Blue Box SIGMA 2002 Installation, Installation, Operating, Operating, And Maintenance Manual

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SIGMA 2002

42 ÷ 297 kW

Installation,Installation,

Installation,

Installation,Installation, operating,operating,

operating,

operating,operating, and maintenanceand maintenance

and maintenance

and maintenanceand maintenance manualmanual

manual

manualmanual

ManualManual

Manual

ManualManual

Issue Replaces

101130A02 101130A02

101130A02

101130A02 101130A02

12.02 12.02

12.02

12.02 12.02

09.98 09.98

09.98

09.98 09.98

Water chillersWater chillers

Water chillers

Water chillersWater chillers

Water/waterWater/water

Water/water

Water/waterWater/water self containedself contained

self contained

self containedself contained

Scroll compressorsScroll compressors

Scroll compressors

Scroll compressorsScroll compressors

ISO 9001 - Cert. n. 0201

00620062

0062

00620062

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INDEX Page

SIGMA 2002 - water chiller 1 TECHNICAL CHARACTERISTICS 1

UNIT FRAME 1 COMPRESSORS 1 EVAPORATOR AND CONDENSER 1 REFRIGERANT CIRCUIT 1 CONTROLS AND SAFETY DEVICES 2 TESTING 2

SIGMA UNIT VERSIONS 2

SIGMA 2002/HP: reverse cycle heat pump 2 SIGMA 2002/LE: motocondensing unit 2 SIGMA 2002/LE/HP: motocondensing unit 2 SIGMA 2002/LC: motoevaporating unit. 2 SIGMA 2002 / LC /HP: motoevaporating unit 2

ACCESSORY VERSIONS 2

SIGMA 2002 /DC: unit with heat recovery condenser. 2 SIGMA 2002 /DS: unit with desuperheaters 2

SIGMA LN: low noise unit 3 REFRIGERANT CIRCUIT ACCESSORIES 3 HYDRAULIC CIRCUIT ACCESSORIES 3 ELECTRICAL ACCESSORIES 3 VARIOUS ACCESSORIES 3 SERIES 4

TECHNICAL DATA Refrigerant R407C 5

ELECTRICAL CHARACTERISTICS Refrigerant R407C 9

TECHNICAL DATA Refrigerant R22 10

ELECTRICAL CHARACTERISTICS Refrigerant R22 14

SOUND POWER AND PRESSURE LEVELS 15

1. SAFETY PRECAUTIONS 16

1.1 DEFINITION OF DANGER ZONE 16

1.2 SAFETY RULES 16 MECHANICAL HAZARDS 17 THERMAL HAZARDS 18 NOISE-RELATED HAZARDS 18 ELECTRICAL HAZARDS 18 REFRIGERANT SAFETY DATA R407C 19 REFRIGERANT SAFETY DATA - R22 21

2. APPLICATION FIELD 23

2.1 GENERAL 23

3. INSPECTION, TRANSPORT, SITE HANDLING 23

3.1 INSPECTION 23

3.2 LIFTING AND SITE HANDLING 23

3.3 UNPACKING 25

3.4 LOCATION 25

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4. INSTALLATION 26

4.1 CLEARANCES 26

4.2 ANTI-VIBRATION ISOLATORS (option) 26

4.2.1 Rubber Anti-Vibration Isolators 26

4.3 WATER PIPING CONNECTIONS 27

4.4 EVAPORATOR WATER PIPE CONNECTIONS 29

4.5 CONDENSER WATER PIPE CONNECTIONS 30

4.5.1 Pressostatic valve 30

4.5.2 3 way valve 31

4.6 DESUPERHEATER HYDRAULIC CONNECTIONS (optional) 32

4.7 HEAT RECOVERY EXCHANGER HYDRAULIC CONNECTIONS (Version /DC) 32

4.8 WATER FLOW SWITCH INSTALLATION INSTRUCTIONS 34

4.9 CONNECTIONS FOR VERSION LE (MOTOCONDENSING) AND LC (MOTOEVAPORATING) 36

4.9.1 Refrigerant connections 36

4.9.2 Route of pipes and maximum distance between sections 36

4.9.3 Procedures to follow when sizing refrigerant lines 36

4.9.4 Version LE: evaporating section at lower level than condensing section: 36

4.9.5 Version LE: evaporating section positioned higher than the condensing unit section 37 TABLE 1 - EXTERNAL PIPE DIAMENTERS FOR VERSIONS LE, LE/HP 37

4.9.6 Version LC: remote condenser above the evaporating unit: 38

4.9.7 Version LC: remote air cooled condenser below the evaporating unit: 38 TABLE 2 - PIPE DIAMETER FOR VERSIONS LC 39

4.9.8 Connection of Sigma 2002 LC/HP units to a remote air cooled condenser. 39 TABLE 3 - CONNECTION PIPE EXTERNAL DIAMETERS FOR VERSIONS LC/HP 40

4.10 PRESSURE RELIEF VALVES 40

4.11 WATER QUALITY 40

4.12 LOW TEMPERATURE WATER AT CONDENSER 41

4.13 OPERATION WITH LOW TEMPERATURE CHILLED WATER AT EVAPORATOR 41 TABLE 4 - FREEZING POINT FOR WATER-ANTIFREEZE MIXTURES 41 OPERATING LIMITS 42

4.14 Water flow rate to evaporato and condenser 43

4.15 EVAPORATOR ChilleD water temperature 43 CONDENSER PRESSURE DROP 43 EVAPORATOR PRESSURE DROP 45

4.16 ELECTRICAL CONNECTIONS 46

4.16.1 General 46

4.16.2 Power supply to crankcase heaters 47

4.16.3 Potential free contacts 47

4.16.4 Flow switch electrical connections 47

4.16.5 Circulating pump electrical connections 47

4.16.6 External interlock 47

4.17 MICROPROCESSOR CONTROLLERS 47

4.17.1 Microprocessor controller for /LE and HP/LE versions 48

4.17.2 RS485 serial interface (optional) 48

5. START-UP 56

5.1 PRELIMINARY CHECKS 56

6 UNIT WITH mCHILLER MICROPROCESSOR (models from 3.2 to 13.2) 57

6.1.1 Display 57

6.1.2 Machine status information 57

6.1.3 Keypad 57

6.1.4 Control and display screens 58

6.1.5 Muting the BUZZER 58

6.1.6 ALARMS reset 58

6.1.7 Activation/deactivation of COOLING operation (summer mode) 59

6.1.8 Activation/deactivation of HEATING mode (winter mode) 59

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6.1.9 Switching off the machine (stand by) 59

6.1.10 Inlet water temperature control 60

6.1.11 Defrosting (only /LC, heat pump units) 60

6.2 STARTING THE UNIT 62

6.3 STOPPING THE UNIT 62

6.3.1 Temporary stop 62

6.3.2 Seasonal stop: 63

6.4 EMERGENCY STOP 63

7. TROUBLESHOOTING 63 8 UNIT WITH pCO2 MICROPROCESSOR (models from 14.4 to 26.4) 71

8.1 General 71

8.1.1 Display 71

8.1.2 Keypad 71

8.2 OPERATING DESCRIPTION 73

8.2.1 Introduction 73

8.2.2 Unit in stand-by mode 73

8.2.3 Enabling the unit 73

8.2.4 Pumps management 73

8.2.5 Compressor start-up 73

8.2.6 Chiller mode operation 73

8.2.7 Heat pump mode operation 74

8.2.8 Evaporator low temperature chilled water protection 74

8.2.9 Evaporator anti-freeze protection electric heater (optional) 74

8.2.10 Compressor operation 74

8.2.11 Compressor management 75

8.2.12 High and low pressure alarms 75

8.2.13 Changeover from chiller to heat pump and vice versa 75

8.2.14 Desuperheater (Option) 75

8.2.15 Total heat recovery (only SIGMA 2002/DC) 75

8.2.16 Dual set-point (option) 76

8.2.17 Leaving water temperature control (option) 76

8.2.18 Defrost (heat pumps units /LC) 76

8.3 STARTING THE UNIT 78

8.4 STOPPING THE UNIT 78

8.4.1 Temporary stop: 78

8.4.2 Seasonal stop: 78

8.5 EMERGENCY STOP 78 9 TROUBLESHOOTING 79 10 CHECKS DURING OPERATION 87

10.1 Checking the refrigerant charge 87

11. CALIBRATION OF CONTROL EQUIPMENT 88

11.1 INTRODUCTION 88 TABLE 5 - CALIBRATION OF CONTROL EQUIPMENT 88 TABLE 6 - CALIBRATION OF SAFETY DEVICES 88

12. MAINTENANCE AND PERIODIC CHECKS 89

12.1 WARNINGS 89

12.2 INTRODUCTION 89

12.3 REPAIRING THE REFRIGERANT CIRCUIT 90

12.3.1 Leak test 90

12.3.2 High vacuum and dehydration of the refrigerant circuit 90

12.3.3 Refrigerant charge 91

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12.4 ENVIRONMENTAL CONSIDERATIONS 91

13. DECOMMISSIONING THE UNIT 92 REFRIGERANT CIRCUIT DIAGRAM 93 DIMENSIONS, WEIGHTS AND HYDRAULIC CONNECTIONS 105

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SIGMA 2002 - water chiller

Water-cooled liquid chillers with hermetic scroll compressors and plate type evaporator, suitable for inside installations.

TECHNICAL CHARACTERISTICS

UNIT FRAME

Self supporting frame, constructed in galvanized sheet steel with RAL 7032 powder paint baked at 180°C to provide a durable weatherproof finish. Models 3.2 to 7.2 and model 14.4 are completely enclosed by painted steel panels fully lined with a sound absorbing material. On models 8.2 to 13.2 only the upper compartment, which contains the compressors, is fully enclosed on all sides by painted steel panels fully lined with a sound absorbing material. On models 8.2 to 13.2 only the upper compartment , which contains the compressors, and the separator between this compartment and the lower part of the unit are enclosed by painted steel panels fully lined with a sound absorbing material. Models 16.4 to 26.4 do not have panels.

COMPRESSORS

Hermetic scroll type with orbital motion, connected in tandem and equipped with oil level sight glass, Klixon internal thermal protection and oil equalisation line.

EVAPORATOR AND CONDENSER

Brazed plate type in 316 AISI stainless steel. Thermal insulation of evaporator is provided by closed cell expanded material. Each evaporator is equipped with a low water temperature probe for freeze protection and each unit is equipped as standard with a mechanical flow switch.

REFRIGERANT CIRCUIT

Comprising: liquid valve, charge connection, liquid sight-glass, filter/dryer, thermostatic expansion valve with external pressure equalisation, high and low pressure switches for 2-compressor models. For 4-compressor models high and low pressure values and relative condensation and evaporation temperatures are measured by pressure transducers that relay the signals to the controller so that they can be read directly on the display. The high pressure side of the circuit is equipped with high pressure switches and relief valves.

ELECTRICAL PANEL

The electrical panel includes:

- main switch

- fuses for the auxiliary and power circuit

- compressor contactors

- microprocessor mCHILLER for 2 compressor units and PCO2 for 4 compressors units, controlling the following functions:

- water temperature regulation

- freeze protection

- compressor time intervals

- compressor start sequence and automatic lead/lag selection

- alarm reset

- common alarm contact for remote signalling

- operating and alarm indicator LEDs

- LCD display of the following information:

- water inlet and outlet temperature

- programmed temperature set-point and differential

- alarms description

- compressor hours run meter for units with PCO2 control

- number of starts of the unit and the compressors

- high and low pressure values and relative condensation and evaporation temperature values.

Electrical power supply [V/f/Hz]: 400/3~/50 ±5%

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CONTROLS AND SAFETY DEVICES

- High pressure switch with manual reset.

- High pressure safety, with manual reset, controlled by the unit controller on four compressors models.

- Low pressure safety switch, with manual reset, controlled by the unit controller for four compressor models, low pressure switch, with manual reset, controlled by the unit microprocessor for the two compressors models.

- High pressure relief valve

- Chilled water temperature sensor (at the evaporator inlet); on four compressors model it is installed on one evaporator only.

- Freeze protection sensor at the outlet of each evaporator.

- Mechanical flow switch supplied as standard as kit with the unit.

- Compressor over-temperature protection

TESTING

The units are subjected to a dry run in the factory and supplied complete with oil and refrigerant.

SIGMA UNIT VERSIONS

SIGMA 2002/HP: reverse cycle heat pump

The heat pump version operates as a water cooled chiller in summer and a water to water heat pump in winter by reversing the refrigerant flow to suit the required operating mode. In addition to the components of version SIGMA 2002, the heat pump version includes: REFRIGERANT CIRCUIT: 4-way reversing valve and a second thermostatic expansion valve. ELECTRICAL PANEL: Microprocessor programmed for summer/winter changeover (the Macroplus microprocessor is used on 4 compressor HP units).

SIGMA 2002/LE: motocondensing unit

The unit is designed to operate with a remotely located refrigerant to air evaporator. It is supplied without a refrigerant to water evaporator and thermostatic expansion valve. The solenoid valve on the liquid line is supplied as standard. Models 3.2 to 13.2 have mchiller control and the remainder of the range is supplied without control. The standard supply is ON/OFF for each compressor from a digital entry.

SIGMA 2002/LE/HP: motocondensing unit

The unit is designed to operate with a remotely located refrigerant to air evaporator. It is supplied without a refrigerant to water evaporator and thermostatic expansion valve. The solenoid valve on the liquid line and liquid receivers are supplied as standard. Models 3.2 to 13.2 have mCHILLER control and the remainder of the range is supplied without control. The standard supply is ON/OFF for each compressor from a digital entry.

SIGMA 2002/LC: motoevaporating unit.

The unit is supplied without a water cooled condenser and is designed to be connected to a remotely located air cooled condenser.

SIGMA 2002 / LC /HP: motoevaporating unit

The unit is supplied without a water cooled condenser and is designed to be connected to a remotely located air cooled condenser. The solenoid valve on the liquid line and the liquid receivers are supplied as standard.

ACCESSORY VERSIONS

SIGMA 2002 /DC: unit with heat recovery condenser.

Not available for HP versions. In addition to the components of version SIGMA 2002 this unit includes a 100% heat recovery condenser, for the production of hot water, and a liquid receiver on each refrigerant circuit.

SIGMA 2002 /DS: unit with desuperheaters

Available for all models. A brazed plate type heat recovery exchanger (desuperheater) is arranged in series with the condenser. Also available on all HP models. In this case an isolating valve must be fitted on the water recovery circuit and be closed during heat pump mode operation as described in the manual.

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SIGMA LN: low noise unit

Low noise units units are completely enclosed with painted steel panels lined with sound absorption material having an intermediate layer of high acoustic impedance material.

REFRIGERANT CIRCUIT ACCESSORIES:

- Compressor suction and discharge valves

Ball valve fitted in the equalisation line

- Pressostatic valve (with solenoid valve on heat pump)

- Liquid line solenoid valve

- Pressure gauges.

On all units with a PCO2 controller the suction and discharge pressures are displayed on the controller. Gauges

on standard units are located inside the compressor compartment.

- Liquid receivers (standard on versions /LE/HP e LC/HP LC/DC e DC)

- Dual set-point.

With double thermostatic expansion valves and solenoid valves, the evaporator of “double set point units” is

sized on the basis of high temperature operation. On units with mCHILLER control, the set must be manually modified on the microprocessor control panel. On units with pCO2 control the two values can be set from the keypad or via a digital input. In all cases the

commutation between the two thermostatic expansion valves is automatic on the basis of the water tempera-

ture. Thermostatic expansion valve selection is made according to the temperature values specified at the time

of order. The operating limits remain unchanged and are as per the catalogue. If glycol is used, in a sufficient

percentage to avoid freezing, the lower limit of the leaving water is extended to a minimum of -5 °C.

- Condenser for well water (only standard version and LE).

HYDRAULIC CIRCUIT ACCESSORIES

- Leaving water temperature control.

Available only on units with control pCO2 (not HP versions).

- Water manifold

(only 4 compressors models). Available for condensers, evaporators and heat recovery.

ELECTRICAL ACCESSORIES

- Power factor correction cos f fg0.9 at nominal operating conditions

- Single voltage-free contacts for machine status signals

- Serial interface. In units with a mCHILLER controller ( 3.2-13.2) the serial interface is the RS485 type with a Carel

protocol. In units with a PC02 control (from 14.4-26.4 excluding HP versions) the serial interface is the RS485

type with a Modbus protocol. Special protocols can be ordered: Carel; Echelon in RS485 or FTT10 versions. HP

units can be supplied with a Macroplus microprocessor controller with a RS422 type serial interface; refer to the

manual enclosed with the unit.

- Remote user terminal panel (in addition to the standard terminal) Not available on HP units (with a Macroplus controller)

- Set point variable with remote signal (0-1V, 0-10V, 0-4mA, 0-20mA) available only on units with a PC0

controller, only in cooling mode. At the time of order. The set point values must be specified at the time of

order.

VARIOUS ACCESSORIES

- Rubber antivibration mountings.

- Timber crate packing

- Pallet/skid for shipment in a container

- Non-standard RAL paint colours

- Unit completely pre-assembled, the unit will be supplied without refrigerant charge, test and PED certificate.

- Modular pre-asembled unit, only 4 compressors models, with the exception of model 14.4.

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SERIES

Press. massima circuito refriger.

Max. Refrigerant circuit pressure

Pression maxi circuit refrigerant

Carica refrigerante per circuito(kg)/Refrigerant charge per circuit

0062

Via Enrico Mattei, 20

REFRIGERANTE

The SIGMA 2002 series of water cooled chillers, for installation inside the building, are available in various sizes with capacities from 42 to 297 kW.

Model designations consist of two numbers:

SIGMA 2002 16.4

Shows the model number of compressors

The model, serial number, characteristics, power supply, etc. are shown by means of decals on the unit.

35028 Piove di Sacco (PD) ITALY

Modello/Model Modell/Modèle

Tensione-Fasi-Frequenza Voltage-Phasses-Frequency Spannung-Phasses-Frequenz Tension-Phasses-Fréquence

Corrente massima assorbita Max absorbed current Maximalstromverbrauch Courant maxi absorbée

Tel. +039.049.9716300

Matricola/Serial number (BBOX) Matrikel/Matricule

Tensione circuiti ausiliari Auxiliary circuit voltage Steuerspannung Tension circuits auxiliares

Corrente massima di spunto Max starting current Max. Anlaufstrom Courant maxi démarrage

0062

A A

Tipo refrigerante Refrigerant type Kältemittel Typ Type de refrigerant

Numero circuiti refrigerante Refrigerant circuit number Anzahl des Kältemittelkreislaufes Numero circuits refrigerant

IP quadro elettrico IP electrical board IP E-Schrank IP tableau electrique

Max. Druck Kältekreislauf

kPa

Press. massima circuito idraulico Max. Hydraultic circuit pressure Max. Druck im Hydraul. Kreislauf Pression maxi circuit hydraulique

Data di produzione Manufacturing date Erstellungsdatum Date de fabrication

bar

kPa bar

Kältemittelfüllung KreislaufCharge de refigerant chaque circuit

/(kg)/(kg)

(kg)

Via Enrico Mattei, 20 35028 Piove di Sacco (PD) ITALY Tel. +039.049.9716300

MODELLO - MODELE - MODEL - TYP

MATRICOLA - MATRICULE - SERIAL NO. - SERIENUMMER

REFRIGERANTE - REFRIGERANT - KÄLTEMITTEL - REFRIGERANT

MODELLO MATRICOLA

MODELLO - MODELE - MODEL - TYP

ESECUZIONE SECONDO

35028 Piove di Sacco (PD) ITALY Tel. +039.049.9716300

NORMATIVE

MATRICOLA - MATRICULE - SERIAL NO. - SERIENUMMER

SCHEMA ELETTRICO SCHEMA FRIGORIFERO SCHEMA IDRAULICO

REFRIGERANTE - REFRIGERANT - KÄLTEMITTEL - REFRIGERANT

DISEGNO MECCANICO

MODELLO MODELE MODEL -TYP

MATRICOLA - MATRICULE SERIAL NO. - SERIENUMMER

Buono di Produzione

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TECHNICAL DATATECHNICAL DATA

TECHNICAL DATA

TECHNICAL DATATECHNICAL DATA

Refrigerant R407CRefrigerant R407C

Refrigerant R407C

Refrigerant R407CRefrigerant R407C

MODEL SIGMA 2002 3.2 4.2 5.2 6.2

Cooling (*) Nominal capacity kW 42,4 51,2 59,8 68,9 Evaporator water flow l/s 2,025 2,445 2,857 3,292

(l/h) 7.290 8.800 10.285 11.851 Evaporator pressure drop kPa 49,9 45,5 39,6 36,2 Condenser water flow l/s 2,497 3,006 3,503 4,045

(l/h) 8.988 10.822 12.612 14.563 Condenser pressure drop kPa 37,9 37,9 39,4 27,1 Heating (**) Nominal capacity kW 51,2 61,7 71,9 83 Condenser water flow l/s 2,447 2,949 3,435 3,967

(l/h) 8.809 10.616 12.367 14.280 Condenser pressure drop kPa 72,5 65,9 57 51,5 Evaporator water flow l/s 1,843 2,216 2,59 2,997

(l/h) 6.636 7.979 9.324 10.788 Evaporator pressure drop kPa 21,2 20,9 22 15,3 Compressors type Quantity n Refrigerant circuits n Absorbed power cooling (*) kW 9,9 11,8 13,5 15,8 Absorbed power heating (**) kW 12,6 15,3 17,7 20,3 Capacity steps % 0-50-100 0-50-100 0-50-100 0-50-100 Refrigerant charge Chiller version kg 1 x 3,8 1 x 4,8 1 x 5,9 1 x 8 ,5 Heat pump version kg 1 x 4,3 1 x 5,1 1 x 6,1 1 x 6 ,6 Oil Oil charge l 2 x 3,3 2 x 3,25 2 x 3,8 1 x 4 + 1 x 3,8 Oil producer Oil type Evaporator type Heat exchanger water volume l 1 x 2,9 1 x 3,8 1 x 4,9 1 x 5,5 Max operating pressure water side bar 30 30 30 30 Condenser type Condenser water volume l 1 x 3,1 1 x 3,9 1 x 4,7 1 x 7,5 Max operating pressure water side bar 30 30 30 30 Dimension and weight Length mm 1.334 1.334 1.334 1.334 Width mm 797 797 797 797 Heigth mm 962 962 962 962 Shipping weight kg 379 403 414 447

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(*) evaporator entering/leaving temperature 12-7 °C; condenser entering/leaving temperature 30-35 °C (**) condenser entering/leaving temperature 40-45 °C; evaporator entering/leaving temperature 15-10 °C.

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TECHNICAL DATATECHNICAL DATA

TECHNICAL DATA

TECHNICAL DATATECHNICAL DATA

Refrigerant R407CRefrigerant R407C

Refrigerant R407C

Refrigerant R407CRefrigerant R407C

MODEL SIGMA 2002 7.2 8.2 9.2 10.2

Cooling (*) Nominal capacity kW 78 89,9 105,9 121,8 Evaporator water flow l/s 3,727 4,296 5,058 5,82

(l/h) 13.418 15.467 18.210 20.953 Evaporator pressure drop kPa 35,4 35 41,4 37 Condenser water flow l/s 4,587 5,291 6,236 7,18

(l/h) 16.513 19.048 22.449 25.849 Condenser pressure drop kPa 26,3 27,5 27,7 30 Heating (**) Nominal capacity kW 94,1 108,7 128,3 147,8 Condenser water flow l/s 4,498 5,193 6,128 7,064

(l/h) 16.193 18.695 22.062 25.429 Condenser pressure drop kPa 50,5 50,2 59,3 53,4 Evaporator water flow l/s 3,404 3,91 4,615 5,32

(l/h) 12.253 14.075 16.613 19.150 Evaporator pressure drop kPa 14,8 15,4 15,6 16,8 Compressors type Quantity n Refrigerant circuits n Absorbed power cooling (*) kW 18 20,8 24,6 28,5 Absorbed power heating (**) kW 22,9 26,9 31,7 36,5 Capacity steps % 0-50-100 0-50-100 0-50-100 0-50-100 Refrigerant charge Chiller version kg 1 x 9,9 1 x 11,4 1 x 12,9 1 x 15,9 Heat pump version kg 1 x 7,7 1 x 9 1 x 10,4 1 x 13 Oil Oil charge l 2 x 4 2 x 6,6 1 x 8 + 1 x 6,6 2 x 8 Oil producer Oil type Evaporator type Heat exch anger water volume l 1 x 6,3 1 x 7,4 1 x 8,4 1 x 10,5 Max operating pressure water side bar 30 30 30 30 Condenser type Condenser water volume l 1 x 8,75 1 x 10 1 x 11,25 1 x 13,75 Max operating pressure water side bar 30 30 30 30 Dimension and weight Length mm 1.334 1.356 1.356 1.356 Width mm 797 768 768 768 Heigth mm 962 1.700 1.700 1.700 Shipping weight kg 470 483 560 648

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TECHNICAL DATATECHNICAL DATA

TECHNICAL DATA

TECHNICAL DATATECHNICAL DATA

Refrigerant R407CRefrigerant R407C

Refrigerant R407C

Refrigerant R407CRefrigerant R407C

MODEL SIGMA 2002 12.2 13.2 14.4 16.4

Cooling (*) Nominal capacity kW 135,2 148,5 156 179,9 Evaporator water flow l/s 6,458 7,095 7,454 8,593

(l/h) 23.247 25.541 26.836 30.934 Evaporator pressure drop kPa 35 36,1 35,4 35 Condenser water flow l/s 7,962 8,743 9,174 10,582

(l/h) 28.663 31.477 33.026 38.096 Condenser pressure drop kPa 31,9 28,5 26,3 27,5 Heating (**) Nominal capacity kW 164,9 182 188,3 217,4 Condenser water flow l/s 7,879 8,693 8,996 10,386

(l/h) 28.363 31.297 32.386 37.391 Condenser pressure drop kPa 51,1 53,1 50,5 50,2 Evaporator water flow l/s 5,939 6,559 6,807 7,82

(l/h) 21.382 23.613 24.506 28.150 Evaporator pressure drop kPa 18,1 16,4 14,8 15,4 Compressors type Quantity n Refrigerant circuits n Absorbed power cooling (*) kW 31,5 34,5 36 41,6 Absorbed power heating (**) kW 40,6 44,7 45,8 53,7 Capacity steps % 0-50-100 0-50-100 0-25-50-75-100 0-25-50-75-100 Refrigerant charge Chiller version kg 1 x 17 ,4 1x 20 ,7 2 x 9,9 2x 11,4 Heat pump version kg 1 x 14,4 1 x 17,8 2 x 7,7 2 x 9 Oil Oil charge l 2 x 8 2 x 8 4 x 4 4 x 6,6 Oil producer Oil type Evaporator type Heat exchanger water volume l 1 x 11,6 1 x 14,3 2 x 6,3 2 x 7,4 Max operating pressure water side bar 30 30 30 30 Condenser type Condenser water volume l 1 x 15 1 x 17,5 2 x 8,75 2 x 10 Max operating pressure water side bar 30 30 30 30 Dimension and weight Length mm 1.356 1.356 1.426 2.476 Width mm 768 768 801 768 Heigth mm 1.700 1.700 1.787 1.700 Shipping weight kg 688 741 810 928

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TECHNICAL DATATECHNICAL DATA

TECHNICAL DATA

TECHNICAL DATATECHNICAL DATA

Refrigerant R407CRefrigerant R407C

Refrigerant R407C

Refrigerant R407CRefrigerant R407C

MODEL SIGMA 2002 18.4 20.4 24.4 26.4

Cooling (*) Nominal capacity kW 211,7 243,6 270,3 297 Evaporator water flow l/s 10,117 11,641 12,915 14,19

(l/h) 36.420 41.906 46.494 51.083 Evaporator pressure drop kPa 41,4 37 35 36,1 Condenser water flow l/s 12,471 14,361 15,924 17,487

(l/h) 44.897 51.698 57.326 62.953 Condenser pressure drop kPa 27,7 30 31,9 28,5 Heating (**) Nominal capacity kW 256,5 295,7 329,8 363,9 Condenser water flow l/s 12,257 14,127 15,757 17,387

(l/h) 44.124 50.858 56.726 62.593 Condenser pressure drop kPa 59,3 53,4 51,1 53,1 Evaporator water flow l/s 9,229 10,639 11,879 13,118

(l/h) 33.226 38.301 42.763 47.225 Evaporator pressure drop kPa 15,6 16,8 18,1 16,4 Compressors type Quantity n Refrigerant circuits n Absorbed power cooling (*) kW 49,3 56,9 63 69 Absorbed power heating (**) kW 63,4 73 81,2 89,3 Capacity steps % 0-25-50-75-100 0-25-50-75-100 0-25-50-75-100 0-25-50-75-100 Refrigerant charge Chiller version kg 2 x 12,9 2 x 15,9 2 x 17,4 2 x 20,7 Heat pump version kg 2 x 10,4 2 x 13 2 x 14,4 2 x 17,8 Oil Oil charge l 2 x 8 + 1 x 6,6 4 x 8 4 x 8 4 x 8 Oil producer Oil type Evaporator type Heat exch anger water volume l 2 x 8,4 2 x 10,5 2 x 11,6 2 x 14,3 Max operating pressure water side bar 30 30 30 30 Condenser type Condenser water volume l 2 x 11,25 2 x 13,7 5 2 x 15 2 x 17 ,5 Max operating pressure water side bar 30 30 30 30 Dimension and weight Length mm 2.476 2.476 2.476 2.476 Width mm 768 768 768 768 Heigth mm 1.700 1.700 1.700 1.700 Shipping weight kg 1.069 1.210 1.226 1.270

plate heat exchanger

scroll

4 2

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160 SZ

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ELECTRICAL CHARACTERISTICS Refrigerant R407C

MODEL SIGMA 2002 3.2 4.2 5.2 6.2

Maximum absorbed power Maximum starting current A 115 150 145 175

Full load current

(2)

Power supply V/f/Hz Control power supply V/f/Hz

(1)

kW 16,4 19,4 24,4 27,3

A 34 40 50 54

400/3~/50

230/~/50

MODEL SIGMA 2002 7.2 8.2 9.2 10.2

Maximum absorbed power Maximum starting current A 179 210 250 265

Full load current

(2)

Power supply V/f/Hz Control power supply V/f/Hz

(1)

kW 30,2 36,2 41,4 46,6

A 58 70 85 100

400/3~/50

230/~/50

MODEL SIGMA 2002 12.2 13.2 14.4 16.4

Maximum absorbed power Maximum starting current A 320 339 237 280

Full load current

(2)

Power supply V/f/Hz Control power supply V/f/Hz

(1)

kW 51,6 56,6 60,4 72,4

A 119 138 116 140

400/3~/50

230/~/50

MODEL SIGMA 2002 18.4 20.4 24.4 26.4

Maximum absorbed power Maximum starting current A 335 365 439 477

Full load current

(2)

Power supply V/f/Hz Control power supply V/f/Hz

(1)

kW 82,8 93,2 103,2 113,2

A 170 200 238 276

400/3~/50

230/~/50

(1) mains power supply to allow unit operation. (2) maximum current before safety cut-outs stop the unit. This value is never exceeded and must be used to size

the electrical supply cables and relevant safety devices (refer to electrical wiring diagram supplied with the unit).

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TECHNICAL DATA Refrigerant R22

MODEL SIGMA 2002 3.2 4.2 5.2 6.2

Cooling (*)

Nominal capacity kW 42,5 51,9 59,1 68,1 Evaporator water flow l/s 2,03 2,48 2,823 3,253

(l/h) 7.309 8.928 10.162 11.710 Evaporator pressure drop kPa 48,3 45,1 37,3 34,1 Condenser water flow l/s 2,497 3,032 3,449 3,981

(l/h) 8.988 10.914 12.416 14.332 Condenser pressure drop kPa 36,5 37,2 36,9 25,3

Heating (**)

Nominal capacity kW 52,4 63,9 72,4 83,5 Condenser water flow l/s 2,505 3,051 3,458 3,989

(l/h) 9.018 10.984 12.450 14.360 Condenser pressure drop kPa 73,1 67,8 55,6 50,2 Evaporator water flow l/s 1,912 2,345 2,661 3,065

(l/h) 6.884 8.443 9.578 11.034 Evaporator pressure drop kPa 21,9 22,5 22,3 15,4 Compressors type Quantity n Absorbed power cooling (*) kW 9,8 11,5 13,1 15,2 Absorbed power heating (**) kW 12,4 14,8 16,7 19,3 Capacity steps % 0-50-100 0-50-100 0-50-100 0-50-100

Refrigerant charge

Chiller version kg 1 x 3,8 1 x 4,8 1 x 5,9 1 x 8,5 Heat pump version kg 1 x 4,3 1 x 5,1 1 x 6,1 1 x 6,6

Oil

Oil charge l 2 x 3,3 2 x 3,25 2 x 3,8 1 x 4 + 2 x 3,8 Oil producer Oil type Evaporator type Heat exchanger water volume l 1 x 2,9 1 x 3,8 1 x 4,9 1 x 5,5 Max operating pressure water side bar 30 30 30 30 Condenser type Condenser water volume l 1 x 1,7 1 x 2,1 1 x 2,5 1 x 1,5 Max operating pressure water side bar 30 30 30 30

Dimension and weight

Length mm 1.334 1.334 1.334 1.334 Width mm 797 797 797 797 Heigth mm 962 962 962 962 Shipping weight kg 379 403 414 447

scroll

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160P

plate heat exchanger

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TECHNICAL DATA Refrigerant R22

MODEL SIGMA 2002 7.2 8.2 9.2 10.2

Cooling (*)

Nominal capacity kW 77,1 88,5 104,5 120,5 Evaporator water flow l/s 3,683 4,228 4,992 5,757

(l/h) 13.257 15.220 17.972 20.725 Evaporator pressure drop kPa 33,4 32,7 39 35 Condenser water flow l/s 4,513 5,185 6,129 7,074

(l/h) 16.248 18.664 22.065 25.465 Condenser pressure drop kPa 24,5 25,5 25,8 28,1

Heating (**)

Nominal capacity kW 94,6 108,4 128,7 148,9 Condenser water flow l/s 4,519 5,18 6,148 7,116

(l/h) 16.269 18.649 22.134 25.619 Condenser pressure drop kPa 49,1 48,1 57,6 52,3 Evaporator water flow l/s 3,469 3,971 4,709 5,447

(l/h) 12.489 14.295 16.952 19.609 Evaporator pressure drop kPa 14,8 15,3 15,6 17 Compressors type Quantity n Absorbed power cooling (*) kW 17,4 20 23,8 27,6 Absorbed power heating (**) kW 22 25,3 30,1 34,9 Capacity steps % 0-50-100 0-50-100 0-50-100 0-50-100

Refrigerant charge

Chiller version kg 1 x 9,9 1 x 11,4 1 x 12,9 1 x 15,9 Heat pump version kg 1 x 7,7 1 x 9 1 x 10,4 1 x 13

Oil

Oil charge l 2 x 4 2 x 6,6 1 x 8 + 1 x 6,6 2 x 8 Oil producer Oil type Evaporator type Heat exchanger water volume l 1 x 6,3 1 x 7,4 1 x 8,4 1 x 10,5 Max operating pressure water side bar 30 30 30 30 Condenser type Condenser water volume l 1 x 1,8 1 x 2 1 x 2,3 1 x 2,8 Max operating pressure water side bar 30 30 30 30

Dimension and weight

Length mm 1.334 1.356 1.356 1.356 Width mm 797 768 768 768 Heigth mm 962 1.700 1.700 1.700 Shipping weight kg 470 483 560 648

scroll

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TECHNICAL DATA Refrigerant R22

MODEL SIGMA 2002 12.2 13.2 14.4 16.4

Cooling (*)

Nominal capacity kW 133,7 146,9 154,2 177 Evaporator water flow l/s 6,389 7,021 7,365 8,455

(l/h) 23.000 25.275 26.514 30.440 Evaporator pressure drop kPa 33,1 34,1 33,4 32,7 Condenser water flow l/s 7,848 8,623 9,026 10,369

(l/h) 28.255 31.044 32.495 37.329 Condenser pressure drop kPa 29,9 26,7 24,5 25,5

Heating (**)

Nominal capacity kW 166,1 183,3 189,2 216,8 Condenser water flow l/s 7,937 8,758 9,038 10,36

(l/h) 28.574 31.528 32.538 37.298 Condenser pressure drop kPa 49,9 51,9 49,1 48,1 Evaporator water flow l/s 6,081 6,716 6,939 7,942

(l/h) 21.893 24.177 24.979 28.590 Evaporator pressure drop kPa 18,3 16,5 14,8 15,3 Compressors type Quantity n Absorbed power cooling (*) kW 30,6 33,5 34,8 40,1 Absorbed power heating (**) kW 38,8 42,7 43,9 50,6 Capacity steps % 0-50-100 0-50-100 0-50-100 0-25-50-75-100

Refrigerant charge

Chiller version kg 1 x 17,4 1x 20,7 2 x 9,9 2x 11,4 Heat pump version kg 1 x 14,4 1 x 17,8 2 x 7,7 2 x 9

Oil

Oil charge l 2 x 8 2 x 8 4 x 4 4 x 6,6 Oil producer Oil type Evaporator type Heat exchanger water volume l 1 x 11,6 1 x 14,3 2 x 6,3 2 x 7,4 Max operating pressure water side bar 30 30 30 30 Condenser type Condenser water volume l 1 x 3 1 x 3,5 2 x 1,8 2 x 2 Max operating pressure water side bar 30 30 30 30

Dimension and weight

Length mm 1.356 1.356 1.426 2.476 Width mm 768 768 801 768 Heigth mm 1.700 1.700 1.787 1.700 Shipping weight kg 688 741 810 928

2 4

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160P

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TECHNICAL DATA Refrigerant R22

MODEL SIGMA 2002 18.4 20.4 24.4 26.4

Cooling (*)

Nominal capacity kW 209 241 267,4 293,9 Evaporator water flow l/s 9,985 11,514 12,778 14,042

(l/h) 35.944 41.449 46.000 50.550 Evaporator pressure drop kPa 39 35 33,1 34,1 Condenser water flow l/s 12,258 14,147 15,697 17,247

(l/h) 44.130 50.931 56.509 62.088 Condenser pressure drop kPa 25,8 28,1 29,9 26,7

Heating (**)

Nominal capacity kW 257,4 297,9 332,3 366,6 Condenser water flow l/s 12,297 14,233 15,874 17,516

(l/h) 44.268 51.238 57.147 63.056 Condenser pressure drop kPa 57,6 52,3 49,9 51,9 Evaporator water flow l/s 9,418 10,894 12,163 13,432

(l/h) 33.904 39.218 43.786 48.354 Evaporator pressure drop kPa 15,6 17 18,3 16,5 Compressors type Quantity n Absorbed power cooling (*) kW 47,6 55,1 61,1 67,1 Absorbed power heating (**) kW 60,3 69,9 77,7 85,5 Capacity steps % 0-25-50-75-100 0-25-50-75-100 0-25-50-75-100 0-25-50-75-100

Refrigerant charge

Chiller version kg 2 x 12,9 2 x 15,9 2 x 17,4 2 x 20,7 Heat pump version kg 2 x 10,4 2 x 13 2 x 14,4 2 x 17,8

Oil

Oil charge l 2 x 8 + 2 x 6,6 4 x 8 4 x 8 4 x 8 Oil producer Oil type Evaporator type Heat exchanger water volume l 2 x 8,4 2 x 10,5 2 x 11,6 2 x 14,3 Max operating pressure water side bar 30 30 30 30 Condenser type Condenser water volume l 2 x 2,3 2 x 2,8 2 x 3 2 x 3,5 Max operating pressure water side bar 30 30 30 30

Dimension and weight

Length mm 2.476 2.476 2.476 2.476 Width mm 768 768 768 768 Heigth mm 1.700 1.700 1.700 1.700 Shipping weight kg 1.069 1.210 1.226 1.270

plate heat exchanger

Maneurop

160P

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ELECTRICAL CHARACTERISTICS Refrigerant R22

MODEL SIGMA 2002 3.2 4.2 5.2 6.2

Maximum absorbed power Maximum starting current A 115 150 145 175

Full load current

(2)

Power supply V/f/Hz Control power supply V/f/Hz

(1)

kW 16,4 18,4 22,8 25,8

A 34 40 50 54

400/3~/50

230/~/50

MODEL SIGMA 2002 7.2 8.2 9.2 10.2

Maximum absorbed power Maximum starting current A 179 210 250 265

Full load current

(2)

Power supply V/f/Hz Control power supply V/f/Hz

(1)

kW 28,8 34 39,9 45,8

A 58 70 85 100

400/3~/50

230/~/50

MODEL SIGMA 2002 12.2 13.2 14.4 16.4

Maximum absorbed power Maximum starting current A 320 339 237 280 Full load current

(2)

Power supply V/f/Hz Control power supply V/f/Hz

(1)

kW 50,6 55,4 57,6 68

A 119 138 116 140

400/3~/50

230/~/50

MODEL SIGMA 2002 18.4 20.4 24.4 26.4

Maximum absorbed power Maximum starting current A 335 365 439 477 Full load current

(2)

Power supply V/f/Hz Control power supply V/f/Hz

(1)

kW 79,8 91,6 101,2 110,8

A 170 200 238 276

400/3~/50

230/~/50

(1) mains power supply to allow unit operation. (2) maximum current before safety cut-outs stop the unit. This value is never exceeded and must be used to size

the electrical supply cables and relevant safety devices (refer to electrical wiring diagram supplied with the unit).

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SOUND POWER AND PRESSURE LEVELS

STANDARD UNITS

Octave band [Hz]

SIGMA

2002

63 dB

Lw Lp Lw Lp Lw Lp Lw Lp Lw Lp Lw Lp Lw Lp Lw Lp Lw Lp

125 250 500 1000 2000 4000 8000

dB dB dB dB dB dB dB

3.2 86,7 71,6 69,5 54,3 67,8 52,6 68,6 53,4 64,1 48,9 60,8 45,6 57,1 41,9 51,7 36,5 70,2 55,0

4.2 86,9 71,8 69,7 54,5 68,0 52,8 68,8 53,6 64,3 49,1 61,0 45,8 57,3 42,1 51,9 36,7 70,4 55,2

5.2 87,0 71,9 69,8 54,6 68,1 52,9 68,9 53,7 64,4 49,2 61,1 45,9 57,4 42,2 52,0 36,8 70,5 55,3

6.2 87,5 72,4 70,3 55,1 68,6 53,4 69,4 54,2 64,9 49,7 61,6 46,4 57,9 42,7 52,5 37,3 71,0 55,8

7.2 87,9 72,8 70,7 55,5 69,0 53,8 69,8 54,6 65,3 50,1 62,0 46,8 58,3 43,1 52,9 37,7 71,4 56,2

8.2 80,3 64,1 72,3 56,0 70,2 54,0 73,4 57,2 69,6 53,4 68,0 51,7 66,5 50,2 63,7 47,5 75,8 59,5

9.2 80,8 64,6 72,8 56,5 70,7 54,5 73,9 57,7 70,1 53,9 68,5 52,2 67,0 50,7 64,2 48,0 76,3 60,0

10.2 81,4 65,2 73,4 57,1 71,3 55,1 74,5 58,3 70,7 54,5 69,1 52,8 67,6 51,3 64,8 48,6 76,9 60,6

12.2 81,7 65,5 73,7 57,4 71,6 55,4 74,8 58,6 71,0 54,8 69,4 53,1 67,9 51,6 65,1 48,9 77,2 60,9

13.2

14.4

16.4

18.4

82,1 65,9 74,1 57,8 72,0 55,8 75,2 59,0 71,4 55,2 69,8 53,5 68,3 52,0 65,5 49,3 77,6 61,3 92,4 76,1 75,1 58,8 73,5 57,1 74,3 57,9 69,8 53,4 66,4 50,1 62,7 46,4 57,4 41,0 75,9 59,5 82,9 65,8 76,3 59,2 79,1 62,0 89,4 72,3 86,9 69,7 89,4 72,3 85,2 68,1 80,1 63,0 94,1 77,0 83,9 66,8 77,3 60,2 80,1 63,0 90,4 73,3 87,9 70,7 90,4 73,3 86,2 69,1 81,1 64,0 95,1 78,0

20.4 84,4 67,3 77,8 60,7 80,6 63,5 90,9 73,8 88,4 71,2 90,9 73,8 86,7 69,6 81,6 64,5 95,6 78,5

24.4 85,1 68,0 78,5 61,4 81,3 64,2 91,6 74,5 89,1 71,9 91,6 74,5 87,4 70,3 82,3 65,2 96,3 79,2

26.4 85,4 68,3 78,8 61,7 81,6 64,5 91,9 74,8 89,4 72,2 91,9 74,8 87,7 70,6 82,6 65,5 96,6 79,5

Total

dB(A)

LOW NOISE UNITS

Octave band [Hz]

SIGMA

2002

63 125 250 500 1000 2000 4000 8000 dB dB dB dB dB dB dB dB dB(A)

Total

/LN Lw Lp Lw Lp Lw Lp Lw Lp Lw Lp Lw Lp Lw Lp Lw Lp Lw Lp

3.2 85,8 70,7 75,5 60,3 67,9 52,7 65,8 50,6 62,1 46,9 58,7 43,5 55,2 40,0 50,2 35,0 68,8 53,6

4.2 86,0 70,9 75,7 60,5 68,1 52,9 66,0 50,8 62,3 47,1 58,9 43,7 55,4 40,2 50,4 35,2 69,0 53,8

5.2 85,9 70,8 75,6 60,4 68,0 52,8 65,9 50,7 62,2 47,0 58,8 43,6 55,3 40,1 50,3 35,1 68,9 53,7

6.2 86,5 71,4 76,2 61,0 68,6 53,4 66,5 51,3 62,8 47,6 59,4 44,2 55,9 40,7 50,9 35,7 69,5 54,3

7.2 86,9 71,8 76,6 61,4 69,0 53,8 66,9 51,7 63,2 48,0 59,8 44,6 56,3 41,1 51,3 36,1 69,9 54,7

8.2 84,0 67,8 74,8 58,5 69,5 53,3 71,6 55,3 66,2 49,9 63,2 47,0 57,8 41,5 50,5 34,3 72,4 56,1

9.2 84,1 67,9 74,9 58,6 69,6 53,4 71,7 55,4 66,3 50,0 63,3 47,1 57,9 41,6 50,6 34,4 72,5 56,2

10.2 84,2 68,0 75,0 58,7 69,7 53,5 71,8 55,5 66,4 50,1 63,4 47,2 58,0 41,7 50,7 34,5 72,6 56,3

12.2 84,5 68,3 75,3 59,0 70,0 53,8 72,1 55,8 66,7 50,4 63,7 47,5 58,3 42,0 51,0 34,8 72,9 56,6

13.2

14.4

16.4

18.4

84,9 68,7 75,7 59,4 70,4 54,2 72,5 56,2 67,1 50,8 64,1 47,9 58,7 42,4 51,4 35,2 73,3 57,0 90,7 74,4 80,4 64,0 72,8 56,4 70,7 54,3 67,0 50,6 63,5 47,2 60,1 43,7 55,1 38,7 73,7 57,3 88,3 71,2 79,1 61,9 73,8 56,7 75,8 58,7 70,4 53,3 67,5 50,4 62,1 44,9 54,8 37,7 76,6 59,5 89,8 72,7 80,6 63,4 75,3 58,2 77,3 60,2 71,9 54,8 69,0 51,9 63,6 46,4 56,3 39,2 78,1 61,0

20.4 90,6 73,5 81,4 64,2 76,1 59,0 78,1 61,0 72,7 55,6 69,8 52,7 64,4 47,2 57,1 40,0 78,9 61,8

24.4 90,9 73,8 81,7 64,5 76,4 59,3 78,4 61,3 73,0 55,9 70,1 53,0 64,7 47,5 57,4 40,3 79,2 62,1

26.4 91,3 74,2 82,1 64,9 76,8 59,7 78,8 61,7 73,4 56,3 70,5 53,4 65,1 47,9 57,8 40,7 79,6 62,5

Lw: sound power values in free field conditions are calculated in accordance with ISO 3746. Lp : sound pressure values measured at 1 m from the unit in free field conditions in compliance with ISO 3746

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1. SAFETY PRECAUTIONS

1.1 DEFINITION OF DANGER ZONE

Only authorised operators must be allowed in the vicinity of the unit.

- The external danger zone concerns a space of approximately 2 m in width around the perimeter of the machine. Access to this area must be prevented by suitable guarding in the event that the unit is located in an unprotected area that is easily accessible to unauthorised persons.

1.2 SAFETY RULES

The unit is designed and built in accordance with the PED 97/23CE rules, to ensure the maximum level of safety. To avoid possible situations of risk adhere to the following rules at all times:

- All work on the unit must be performed by qualified personnel. Before working on the unit, ensure that the designated personnel are conversant with the documentation supplied. Always ensure there is a copy of the documentation in the immediate vicinity of the unit.

- Use the appropriate personal safety equipment (gloves, helmet, safety goggles, safety footwear, etc.) for all maintenance and control operations on the unit.

- Use only tools and equipment that are in good working order.

- The compressor compartment contains various high temperature components. Adopt the maximum caution when working in the vicinity of the compressors and avoid touching any parts of the unit without appropriate protection.

- Pipe the discharge of the relief valves.

- Do not work within the theoretical discharge trajectory of the relief valves.

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MECHANICAL HAZARDS

The pipes are rigidly anchored to reduce

Operating mode Analysed risk or hazard Solution adopted

Normal operating regime Maintenance

Handling during transport and installation.

Normal Operating regime Maintenance Normal Operating regime

Maintenance Surfaces, sharp corners edges. In the interior parts of the unit it is not

Normal Operating regime Maintenance Cutting or severing. The inside part of the unit does not have Normal operating regime Maintenance Entanglement, dragging, Normal Operating regime Maintenance

Stability Because of their intrinsic characteristics, the

units are not associated with problems of possible falling or tipping while in operation. However, you must carefully read the descriptions given in this manual concerning the methods of positioning the unit.

Stability The unit's base frame has specific lifting

holes, the positions of which are marked with yellow decals, designed to eliminate the risk of the unit tipping.

Pipe bursts.

vibration, a major cause of pipe fracture. Surfaces, sharp corners and edges.

Cutting or severing. The inside part of the unit does not have

Entanglement, dragging, impact.

impact. Projection of high pressure jets of fluid - Explosion hazard

The machine is designed and manufactured

to minimise the presence of sharp corners

and edges as far as possible. If the unit is

located in areas easily accessible by non

qualified people provide suitable protection.

possible to completely eliminate risks derived

from the presence of surfaces, sharp corners

and edges. For this reason the user,

installation, and maintenance manual

specifies that maintenance operations be

carried out exclusively by qualified personnel,

simultaneously providing indications on the

protection to be utilised.

moving parts

The inside part of the unit does not have

moving parts

The inside part of the unit does not have

moving parts

All units are equipped with relief valves to

eliminate the risk of explosion.

The outlet from the relief valves must be

piped appropriately to eliminate risks of

expulsion of high pressure gas from the

machine. The warnings regarding this

discharge are fixed to the unit and given in

the use and maintenance manual.

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THERMAL HAZARDS

Operating mode Analysed risk or hazard Solution adopted

Normal operating regime

Maintenance

Burns caused by high temperatures.

NOISE-RELATED HAZARDS

Operating mode Analysed risk or hazard Solution adopted

Normal operating regime Maintenance

Hearing damage. All units are designed and manufactured

Most of the pipes that could cause burns are lagged with thermo insulating material. If the unit is positioned in locations easily accessible by non qualified people provide suitable protection. Most of the pipes that could cause burns are lagged with thermo insulating material. If the unit is positioned in locations easily accessible by non qualified people provide suitable protection.

with to reduce noise emissions to the minimum.

ELECTRICAL HAZARDS

Operating mode Analysed risk or hazard Solution adopted

Operating regime Maintenance

Contact with live electrically components (direct contact).

Elements carrying electrical current in the case of faults.

Inappropriate insulation.

Radiated heat due to shortcircuits or overloads.

The units are designed and built in compliance with harmonised standard EN 60204-1.

HAZARDS PRODUCED BY SUBSTANCES

Operating mode Analysed risk or hazard Solution adopted

Normal operating regime Maintenance

contained in the unit See safety sheets of refrigerants R407C and

R22

FURTHER HAZARDS

o eliminate any further hazard it is necessary to provide adequate protection to avoid access to the unit by non qualified people.

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REFRIGERANT SAFETY DATA R407C

1. IDENTIFICATION OF THE SUBSTANCE

2. COMPOSITION / INFORMATION ON INGREDIENTS

3. HAZARDS IDENTIFICATION:

4. FIRST-AID MEASURES:

5. FIRE-FIGHTING MEASURES:

6. ACCIDENTAL RELEASE MEASURES:

Identification of the

1.1 preparation: Synonyms: HFC-32lHFC-125IHFG134a Formula: Mixture EE-No: difluoromethane (HFC-32) : 200-839-4

Chemical Name CAS-No - Wt % - Symbol(s): & phrases "R" difluoromethane 75/10/5 - 23 - F+;R12 1-2-2-2-tetrafluoroethane 811/97/2 - 52 pentafluoroethane 354/33/ 6 - 25

3.1 Most important hazards:

Eyes Rinse immediately with plenty of water for at least 15 minutes.

4.1

Skin Liquefied gas may cause frostbite. Wash frostbitten areas with

Inhalation Move to fresh air in case of accidental inhalation of vapours.

Ingestion Do not induce vomiting without medical advice. Call a physician

General advice Consult a physician alter significant exposure.

5.1 Suitable extinguishing media:

5.2 Extinguishing media which must not be used for safety reasons:

5.3 Specific hazards: Possibility of generating hazardous reactions during a fire due to

5.4 Special protective equipment for firefighters:

5.5 Specific methods: Standard procedure for chemical fires. In the event of fire, cool

6.1 Personal precautions: Use personal protective equipment. Evacuate personnel to safe

6.2 Methods for cleaning up:

407C

1-1-1-2-tetrafluoroethane UHFC-134a) : 212-377-0 pentafluoroethane (HFC-125) : 206-557-8

Liquefied gas: may cause frostbite. Contact with eyes may cause irritation.

Keep eye wide open while rinsing. If symptoms persist, call a physician.

plenty of water. Do not remove clothing. Wash off with warm water. if skin irritation persists, call a physician.

Oxygen or artificial respiration if needed. Do not apply artificial respiration if patient is breathing; Consult a physician after significant exposure. Do not give adrenaline or similar drugs.

immediately. Do not give drugs from adrenaline-ephedrine group.

The product itself does not burn. Extinguish with carbon dioxide, dry chemical, foam or water spray. Use extinguishing measures that are appropriate to the environment. None

the presence of F and/or Cl groups. Fire or intense heat may cause violent rupture of packages. In case of fire, west a self contained breathing apparatus. Protective suit.

tanks with water spray.

areas. Do not breath vapours or spray mist. Ensure adequate ventilation. Shut off leaks it without risk. Solid evaporates. Ensure adequate ventilation.

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REFRIGERANT SAFETY DATA R407C

7. HANDLING AND STORAGE:

8. EXPOSURE CONTROLS / PERSONAL PROTECTION:

9. STABILITY AND REACTIVITY:

10. TOXICOLOGICAL INFORMATION:

11. DISPOSAL CONSIDERATIONS:

INFORMATIQN:

7.1 Handling: Keep away from heat, sources of ignition. Do not puncture or drop container, Provide sufficient air exchange and / or exhaust in work rooms.

7.2 Storage: Keep containers tightly closed in a cool, well-ventilated place. Store in a cool and shaded area. Do not expose to temperatures above 50 °C. Keep tightly closed.

8.1 Engineering measures

to reduce exposure: Personal protection

8.2

equipment: Respiratory protection: In case of insufficient ventilation wear suitable respiratory

Hand protection: Impervious butyl rubber gloves. Eye protection: Wear as appropriate: safety glasses, gaggles, Wear face-shield

Skin and body protection:

8.3 Exposure limit(s): 1-1-1-2-tetrafluoroethane 1000 ppm (TWA);

9.1 Stability: Stable at normal conditions. No decomposition if stored and

9.2 Conditions to avoid: Do not expose to temperatures above 50 °C. Fire or Intense heat

9.3 Materials to avoid: alkaline metals (Na, K), alkaline earth metals (Ca, Mg), finely

9.4 Hazardous

decomposition products:

10.1 Acute toxicity: LC50/inh./4 h/rat : > 500000 ppm

10.2 Irritation :

Skin: slightly irritant, may cause frostbite. Eyes: slightly irritant.

10.4 Chronic toxicity: chronic inhalation, no-observed-effect level (NOEL):> 10000pprn

11.1 Waste from residues /

unused products:

Contaminated

packaging:

No. O.N.U. 3340 12. TRANSPORT ADR/RID UN 3340 Refrigerant gas R407C, 2, 2° A, ADR/RID

Ensure adequate ventilation, especially in confined areas.

equipment, preferably a compressed airline breathing apparatus.

and protective suit for abnormal processing problems. Chemical resistant apron, long sleeved clothing, safety shoes.

difluoromethane: 1000 ppm (TWA); pentafluoroethane: 1000 ppm (TWA)(AIHA);

applied as directed. Decomposition starting from 250°C. may cause violent rupture of packages. divided aluminium, zinc.

halogenated compounds, hydrogen halides (HF, HCI), carbonyl halides (COCl2), carbon monoxide, carbon dioxide (C02).

rat.

Offer surplus and non-recyclable solutions to an established disposal company. In accordance with local and national regulations. S59 - Refer to manufacturer/supplier for information on recovery/recycling. Do not reuse empty containers. Empty pressure vessels should be returned to supplier.

Label: 2

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REFRIGERANT SAFETY DATA - R22

1. IDENTIFICATION OF THE SUBSTANCE

INGREDIENTS

3. HAZARDS 3.1 Major hazards: Causes damage to ozone layer.

4. FIRST-AID MEASURES:

5. FIRE-FIGHTING MEASURES:

6. ACCIDENTAL RELEASE MEASURES:

Identification of the

1.1 preparation: Synonyms: chlorodifluoromethane Formula: CHClF2 CAS-No 75-45-6 EEC-No 200-871-9

Chemical Name CAS-No - Wt % - Symbol(s): & phrases "R" 2. COMPOSITION / Chlorodifluoromethane 75/45/6 - 100 - R59

Eyes Rinse immediately with plenty of water for at least 15 minutes.

4.1

Skin Liquefied gas may cause frostbite. Wash frostbitten areas with

Inhalation Move to fresh air in case of accidental inhalation of vapours. Use

Ingestion Do not induce vomiting without medical advice. Call a physician

General advice Consult a physician alter significant exposure.

5.1 Suitable extinguishing media:

5.2 Extinguishing media which must not be used for safety reasons:

5.3 Specific hazards: Possibility of generating hazardous reactions during a fire due to

5.4 Special protective equipment for firefighters:

5.5 Specific methods: Standard procedure for chemical fires. In the event of fire, cool

6.1 Personal precautions: Use personal protective equipment. Evacuate personnel to safe

6.2 Methods for cleaning up:

HCFC-22

Keep eyes wide open while rinsing. If symptoms persist, call a physician.

plenty of water. Do not remove clothing. Wash off with warm water. if skin irritation persists, call a physician.

oxygen or artificial respiration if needed. Do not apply artificial respiration if patient is breathing; Consult a physician after significant exposure. Do not give adrenaline or similar drugs.

immediately. Do not give drugs from adrenaline-ephedrine group.

The product itself does not burn. Extinguish with carbon dioxide, dry chemical, foam or water spray. Use extinguishing measures that are appropriate to the environment. None

the presence of F and/or Cl groups. Fire or intense heat may cause violent rupture of containers. In case of fire, wear a self contained breathing apparatus. Protective suit.

tanks with water spray.

areas. Do not breath vapours or spray mist. Ensure adequate ventilation. Shut off leaks if without risk. Solid evaporates. Ensure adequate ventilation.

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REFRIGERANT SAFETY DATA - R22

7. HANDLING AND STORAGE:

8. EXPOSURE CONTROLS / PERSONAL PROTECTION:

9. STABILITY AND REACTIVITY:

10. TOXICOLOGICAL INFORMATION:

11. DISPOSAL CONSIDERATIONS:

INFORMATIQN:

7.1 Handling: Keep away from heat, sources of ignition. Do not puncture or drop container. Provide sufficient air exchange and / or exhaust in plant rooms.

7.2 Storage: Keep containers tightly cl osed in a cool, well-ventilated place. Store in a cool and shaded area. Do not expose to temperatures above 50 °C. Keep tightly closed.

8.1 Engineering measures

to reduce exposure: Personal protection

8.2

equipment: Respiratory protection: In case of insufficient ventilation wear suitable respiratory

Hand protection: Impervious butyl rubber gloves. Eye protection: Wear as appropriate: safety glasses, goggles, Wear a face-shield

Skin and body protection:

8.3 Exposure limit(s): Chlorodifluoromethane: 3600 mg/m3, 1000 ppm (TLV)

9.1 Stability: Stable

9.2 Conditions to avoid: Keep well clear of naked flame and sparks. Do not smoke. If

9.3 Materials to avoid: alkaline earth metals, alkaline metals, aluminium precipitate, zinc.

9.4 Hazardous

decomposition products:

10.1 Acute toxicity: LC50/inh./4 h/rat : > 300,000 ppm

10.2 Irritation:

10.3 Sensitisation: Hearth sensitisation: 50,000 ppm

10.4 Chronic toxicity: Sub-chronic exposure, effects not observed below level (NOEL):

11.1 Waste from residues /

unused products:

Contaminated

packaging:

No. O.N.U. 1018 12. TRANSPORT ADR/RID UN 1018 Chlorodifluoromethane, 2, 2° A, ADR/RID

Ensure adequate ventilation, especially in confined areas.

equipment, preferably a compressed airline breathing apparatus.

and protective suit for abnormal processing problems. Chemical resistant apron, long sleeved clothing, safety shoes.

burned, the product can give off toxic fumes . use self-contained breathing apparatus.

halogenated compounds (e. g. acids), carbonyl halides.

10,000 ppm

Label: 2

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2. APPLICATION FIELD

SIGMA 2002 units have been designed for cooling water or water-glycol and are generally used in air conditioning or refrigeration applications. See chapter 6 for recommended operating ranges.

2.1 GENERAL

- When installing or servicing the unit, it is necessary to strictly follow the rules described in this manual, to conform to all the items detailed on the unit labels and take any necessary precaution.

- Pressure in refrigerant circuits and danger from electrical shock can be hazardous when installing or servicing the unit.

Any work on the unit must be carried out by trained people only.

The warranty will be invalid if the rules described in this manual are not observed and if any modifications are made to the unit without prior authorisation of the manufacturer.

Attention: before repairing or servicing the unit, ensure that the electrical supply is disconnected.

3. INSPECTION, TRANSPORT, SITE HANDLING

3.1 INSPECTION

After receiving the unit, immediately check its integrity. The unit will have left the factory in perfect condition. Therefore on receiving the unit any damage must be verbally described to the carrier and recorded on the Delivery Note before it is signed by both parties. Blue Box or their Agent must be informed as soon as possible of the extent of the damage. The Customer should prepare a written statement and photographic evidence regarding any severe damage.

3.2 LIFTING AND SITE HANDLING

Avoid sudden movements and jolts when unloading and positioning the unit. Internal handling procedures must be conducted with care. Do not exert leverage on the components of the machine. The unit must be lifted by inserting steel tubes through the lifting attachments shown by the relative signs (yellow arrow). The unit must be lifted by harnessing it as shown in figure 1: use ropes or straps of sufficient length and spacer bars to avoid damage to the unit’s side panels and cover. Alternatively, the unit (with a maximum length less than

3.5 m) can be lifted by a forklift truck, inserting the forks under the pallet.

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Caution: ensure that the method of lifting does not allow the unit to slip from chains and slings and does not allow the unit to turn over or slide from lifting devices.

Side protection (not supplied)

Space bars (not supplied)

2 m min.

Space bars (not supplied)

2 m min.

Figure 1

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3.3 UNPACKING

When unpacking the unit pay attention not to damage the unit. Packaging consists of different materials: wood, paper, nylon etc. Separate the materials and deliver to the proper gathering centre in order to reduce their environmental impact.

3.4 LOCATION

The unit is suitable for inside locations where the temperature never falls below 4 °C. Unit vibration is very low. However it is advisable, to fit a rigid rubber pad between the floor or basement and unit base-frame. If very low levels of vibration are required spring or rubber anti-vibration isolators should be installed. For details see paragraph 4.2.

Rubber pad

Slab

Figure 2

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4. INSTALLATION

4.1 CLEARANCES

Minimum clearances for all units should be as follows:

- Long side: 800 mm to allow hydraulic connection to the system and servicing operations;

- Front side: 800 mm to allow access to electric board;

- Rear side: 800 mm to allow maintenance operations;

- Above the unit: 1000 mm.

800

Figure 3

4.2 ANTI-VIBRATION ISOLATORS (option)

It is recommended that the unit is installed on rubber or spring anti-vibration mountings, supplied as an option, to reduce vibrations transmitted to the building structure. It is advisable to use rubber isolators for units installed in the basement, or ground floors in contact with the earth, and spring isolators for units installed on intermediate floors.

The anti-vibration isolators must be installed before the unit is positioned. Ensure that during lifting the unit is firmly secured with straps.

4.2.1 Rubber Anti-Vibration Isolators

Rubber isolators are made of an upper metallic bell with a fixing screw to the base-frame of the unit. The isolator is fixed at the foundation via 2 holes on the flange. On the flange there is a number (45, 60, 70 ShA) which identifies the hardness of the rubber isolator. The dimensional drawing, enclosed in the machine, shows the unit footprint with the position and weight of each isolator.

Rubber/metal anti-vibration isolator

Designed to reduce the vibration.

Figure 4

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4.3 WATER PIPING CONNECTIONS

Unit water pipework must be installed in accordance with national and local regulation and codes. Follow the recommendations below when designing the water piping circuit (refer to the diagrams included in this manual).

- Piping should be connected to the unit with flexible joints, to avoid vibration transmission and allow for thermal expansion (the same procedure should be adopted for the circulating pumps).

- The following devices should be located on the piping system:

- isolating/regulating valves, temperature gauges or thermometer pockets, pressure gauges or binder points required for servicing operations.

- Serviceable mesh strainer, with a filtration level no larger than 1mm, located on the unit inlet to prevent debris from entering the heat exchangers.

- vent valves, to be installed in the upper parts of the circuit, for air bleeding.

- expansion device with accessories for circuit pressurisation, water thermal expansion compensation and system filling.

- unload valve and if necessary drainage tank for circuit emptying during maintenance and seasonal stop.

It is recommended that a safety valve is installed that can discharge the system in dangerous situations such as fire. The valve must be connected to a vent pipe with a cross sectional area equal to or greater than the valve and must be directed into a safe zone where people cannot be injured.

In all units with four compressors the water inlets and outlets of the condensers, evaporators and heat recovery heat exchangers must be connected together with a manifold (available as an option).

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8 Thermometer

9 Water filter

10 Vent valve

11 Flexible connection

12 System filling valve

2 Expansion tank

3 Safety valve

4 Check valve

1 Circulating pump

5 Ball valve

* Only HP version

13 Water drain

14 Flow switch

6 Tank

7 Water gauge

SUGGESTED HYDRAULIC CIRCUIT DIAGRAM FOR UNITS SIGMA 2002

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LEGEND

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4.4 EVAPORATOR WATER PIPE CONNECTIONS

The water inlet and outlet must be connected in the positions indicated as labelled on the unit.

EVAPORATOR WATER

If incorrectly connected the antifreeze thermostat will not operate and the evaporator may freeze. The hydraulic connections are threaded. The type and size are indicated on the dimensional drawings at the end of this manual.

A constant water flow to the evaporator must be guaranteed at all operating conditions to prevent liquid refrigerant from entering the compressor and causing irreparable damage.

Compressors start and stop often due to changes in cooling demand. In hydraulic circuits with low water volume, where the thermal inertia action is low, it is advisable to verify that the water volume equals or exceeds the following ratio:

24 · Q

COMPTOT

M>= ---------------------

where:

M = system water content [kg]

COMPTOT

= unit cooling capacity [kW]

N = number of capacity steps

If the water volume does not reach the value given by the formula, it is advisable to provide the circuit with a storage vessel to increase the volume (tank + circuit) to match the result of the formula. The chilled water piping and storage vessel must be insulated to prevent condensation on the pipe surfaces and to avoid circuit performance losses.

On all units it is compulsory to install a flow switch. If a flow switch is not installed, on the evaporator leaving water connection, the warranty will be terminated immediately. The flow switch must be installed, by the contractor, on the evaporator water outlet connection labelled with:

EVAPORATOR WATER

HEAT PUMP units require a second flow switch is provided with the unit. This must be installed, by the contractor, on the condenser outlet connection labelled with:

CONDENSER WATER

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All units are equipped with plate heat exchangers. It is compulsory to install a metallic filter, on the water inlet piping, with a mesh not larger than 1 mm. If a filter is not installed the warranty will be terminated immediately.

We strongly recommend installing a pressure relief valve on the hydraulic circuit. In the event of serious system breakdown or emergency (e.g. fire), the relief valve will make it possible to depressurise the system thus forestalling possible pipe bursts. Always connect the relief valve outlet to a pipe of diameter no smaller than the valve opening, and route it to a location in which persons are protected from the jet of expelled water.

Caution: When making hydraulic connections never use naked flames close to or inside the unit.

4.5 CONDENSER WATER PIPE CONNECTIONS

The water inlet and outlet must be connected in the positions indicated as labelled on the unit.

ACQUA CONDENSAZIONE

CONDENSER WATER

All units are provided with stainless steel threaded hydraulic connections. Sizes and locations are indicated in the dimensional data at the end of this manual.

For units equipped with more than one compressor, water inlets and outlets must be manifolded together. For connection locations and dimensions see the dimensional drawings at the end of this manual.

4.5.1 Pressostatic valve

When using city water, rather than a cooling tower, it is recommended that a pressostatic valve is installed to ensure the correct operation of the unit. The pressostatic valve is also recommended for closed circuit installations. This valve guarantees regular operation of the unit with changing condenser water conditions (for example when restarting after a weekend pause). The pressostatic valve is absolutely necessary if the tower water entering into the condenser can decrease below 20 °C (see figure 5). The pressostatic valve must provide a condensing pressure higher than 12.5 bar relative. Consult Blue Box for further information.

ACQUA CONDENSAZIONE

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Pressostatic valve

Refrigerant gas inlet

Condenser water outlet

Condenser water inlet

Refrigerant gas outlet

1 Condenser 2 Pressostatic valve 3 Pocket

Figure 5

4.5.2 3 way valve

A three way modulating valve, with temperature probe fitted on the condenser water inlet, can be provided, instead of the pressostatic valve, to maintain the inlet condenser water temperature higher than 20 °C. (See figure 6).

Refrigerant gas inlet

Condenser water outlet

Condenser water inlet

Refrigerant gas outlet

1 Condenser 2 3 vay valve 3 Circulating pump

Figure 6

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4.6 DESUPERHEATER HYDRAULIC CONNECTIONS (optional)

For units provided with desuperheaters it is recommended that a pressostatic or three way modulating valve is installed with a temperature sensor fitted on the condenser water inlet.

The water inlet and outlet must be connected in the positions indicated as labelled on the unit.

ACQUA DESURRISCALDATORE

WATER DESUPERHEATER

OUT

ACQUA DESURRISCALDATORE

In this way the system will be kept under optimal operating parameters. See paragraph 4.5.

In HP version units the hydraulic connections of the desuperheater must be isolated when working in heat pump mode.

4.7 HEAT RECOVERY EXCHANGER HYDRAULIC CONNECTIONS (Version /DC)

For all units equipped with a heat recovery condenser, the hydraulic circuit connections are male threaded steel pipes. These units are equipped with a sensor monitoring the temperature of water returning from the system. The microprocessor controller enables heat recovery when required, and restarts regular operation once the water has reached the setpoint temperature. If faults occur on the recovery condenser the microprocessor controller restarts the cooling through the condenser. The calibration values of the thermostat and pressure switches are given in the specific controller instruction manual.

The water inlet and outlet must be connected in the positions indicated as labelled on the unit.

ACQUA RECUPERO

RECOVERY WATER

OUT

To ensure that the unit operates at optimal parameters in the heat recovery mode, the condensing temperature must be maintained at around 53 °C. The leaving water temperature from recovery condenser must be between the limits of the "OPERATING LIMITS" diagram (T min. out = 25 °C, T max out = 50 °C). Water flow to the main condenser and recovery condenser must be controlled in order to obtain the set recovery temperature and always maintain the condensing pressure higher than 12.5 bars.

The hydraulic circuits to main condenser and recovery condenser will therefore have variable water flows. To keep the condensing pressure higher than 12.5 bars, two possible solutions are suggested:

- with pressostatic valve (See figure 7)

- with 3 way valve (See figure 8)

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DIAGRAM WITH PRESSOSTATIC VALVE

Refrigerant gas inlet

Uscita acqua recupero

Ingresso acqua recupero

Condenser water outlet

Condenser water inlet

1 Heat recovery condenser 2 Main condenser 3 Pressostatic valve 4 Pocket

Refrigerant gas outlet

DIAGRAM WITH 3 WAY VALVE

Refrigerant gas inlet

Figure 7

Heat recovery water outlet

Heat recovery water inlet

1 Heat recovery condenser 2 Main condenser 3 3 way valve 4 Circulating pump 5 3 way valve

Condenser water outlet

Refrigerant gas outlet

Condenser water inlet

Figure 8

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4.8 WATER FLOW SWITCH INSTALLATION INSTRUCTIONS (supplied as a kit for each evaporator)

- Clean the piping system into which the flow switch is to be fitted and remove any magnetic particles, such as welding residues etc.

- To prevent turbulent flow there must be straight pipework, equal to 5 times the diameter of the pipe, either side of the flow switch.

" Connect the "T" shaped metallic manifold (on which the flow switch is mounted) into the evaporator male

threaded water outlet labelled with:

EVAPORATOR WATER

For HEAT PUMP units, repeat the operation and screw the "T" shaped brass manifold (on which the second flow switch is mounted) into the condenser male threaded water outlet labelled with:

CONDENSER WATER

To avoid leakage, seal the connection by using teflon. The flow switch should be installed on the heat exchanger that is closer to the electrical board.

Heat pump version only

Heat exchanger (condenser)

Heat exchanger

Hole for electrical cable

Connect to terminal box

Heat exchanger (evaporator)

Heat exchanger (condenser)

Heat exchanger (evaporator)

Figure 9

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- The flow switch must be tightened on the “T” shaped metallic manifold by the plastic knurled union nut. Check that the arrow located on the upper side is pointing in the direction of flow.

- Be sure to fit the O-ring seal, through the brass manifold and the plastic ring nut. The O-ring seal is supplied in a plastic cover to protect the flow switch shaft.

- Connect the flow switch to the other end of the “T” manifold.

- Route the flow switch electrical cable through the hole in the unit structure and run it to the electrical panel by ascending the upright in the machine interior. Connect the flow switch to terminals 1-14 as indicated on the electrical drawing.

- The flow switch can be removed by screwing out the plastic knurled union nut. In order to reassemble it, ensure that the o-ring seal is positioned in the proper location. (See figure10).

Arrow

Flow switch

Electric cable

Plastic union nut

O Ring

Flow direction

“T” shaped brass manifold

Figure 10

Warning: When connecting or fabricating pipework never work with naked flames either inside the unit or in the immediate vicinity of the unit.

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4.9 CONNECTIONS FOR VERSION LE (MOTOCONDENSING) AND LC (MOTOEVAPORATING)

4.9.1 Refrigerant connections

Version LE units (motocondensing) and LE (motoevaporating) must be connected with refrigerant pipelines.

4.9.2 Route of pipes and maximum distance between sections

For units types with separate sections, the route followed by refrigerant lines depends on the location of the sections and the characteristics of the surrounding building structure. Pipe runs should be as short as possible to limit the pressure drop and the refrigerant charge volume. The maximum permissible pipeline length is 30 metres. If this limits cannot be adhered to contact Blue Box for further information.

4.9.3 Procedures to follow when sizing refrigerant lines

Depending on the relative position of the sections, there are certain procedures to follow when installing the refrigerant line.

The diameter of pipes for versions LE and LC can be obtained from tables 1, 2 and 3, according to the selected model and length of connecting pipes.

4.9.4 Version LE: evaporating section at lower level than condensing section:

a) The vertical riser must be equipped with siphons at least every 6 metres to facilitate the return of oil to the

compressor; b) Make a collection pit on the suction line downstream of the thermostatic valve bulb; c) Horizontal sections of the suction line should follow a grade of at least 1% to facilitate oil return to the

compressor (see above).

Figure 11

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4.9.5 Version LE: evaporating section positioned higher than the condensing unit section

a) Form a siphon on the suction line, at the same height as the evaporator, to avoid drainage of liquid towards the

compressor when the unit is stopped.

b) Make a collection pit on the suction line, downstream from the thermostatic valve bulb, for the collection of

liquid refrigerant that can accumulate during unit shutdown. When the compressor restarts the refrigerant will evaporate rapidly: it is advisable to create the accumulation pit well away from the bulb to avoid the risk of affecting the operation of the thermostatic valve.

c) Horizontal sections of the suction line should follow a grade of at least 1% to facilitate oil return to the

compressor.

Figure 12

TABLE 1 - EXTERNAL PIPE DIAMENTERS FOR VERSIONS LE, LE/HP

Distance between unit and remote evaporator [m]

10 20 30

MODEL

SIGMA 2002/LE

Suction Liquid Suction Liquid Suction Liquid

[mm] [mm] [mm] [mm] [mm] [mm]

3.2 35 18 35 18 42 18

4.2 35 22 42 22 42 22

5.2 35 22 42 22 42 22

6.2 42 22 42 22 42 22

7.2 42 28 42 28 42 28

8.2 42 28 54 28 54 28

9.2 54 28 54 28 54 28

10.2 54 28 54 28 54 28

12.2 54 35 54 35 54 35

13.2 54 35 67 35 67 35

14.4 42 28 42 28 54 28

16.4 42 28 54 28 54 28

18.4 54 28 54 28 54 28

20.4 54 28 54 28 54 28

24.4 54 35 54 35 67 35

26.4 54 35 67 35 67 35

Diameter connection pipes between unit

and remote evaporator

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4.9.6 Version LC: remote condenser above the evaporating unit:

a) Make a trap on the supply line, immediately downstream from the compressor, to collect the liquid refrigerant

which can develop during unit shutdown and could irreparably damage the compressor. b) Install siphons at least every 6 metres on vertical upward sections of pipelines in order to facilitate the return of

oil to the compressor. c) Ensure that there is a gradient of at least 1% on horizontal sections of the refrigerant lines to facilitate oil

drainage in the correct direction of the flow. d) Install a non return valve close to condenser inlet, to avoid liquid refrigerant entering the compressor during unit

shutdown. This must be done with the unit off and when the ambient temperature of the condenser is higher

than that of the compressor.

Figure 13

4.9.7 Version LC: remote air cooled condenser below the evaporating unit:

There are no special suggestions for this installation. It is however advisable to install a non return valve close to the compressor inlet, to avoid liquid refrigerant entering the compressor during unit shutdown. This must be done with the unit off and when the ambient temperature of the condenser is higher than that of the compressor.

Figure 14

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TABLE 2 - PIPE DIAMETER FOR VERSIONS LC

Distance between unit and remote air cooled condenser [m]

10 20

MODEL

SIGMA 2002/LC

Delivery Liquid Delivery Liquid Delivery Liquid

[mm] [mm] [mm] [mm] [mm] [mm]

3.2 22 16 22 16 22 16

4.2 22 18 22 18 22 18

5.2 22 18 22 18 28 18

6.2 28 22 28 22 28 22

7.2 28 22 28 22 28 22

8.2 28 22 28 22 28 22

9.2 35 28 35 28 35 28

10.2 35 28 35 28 35 28

12.2 35 28 35 28 35 28

13.2 35 28 35 28 35 28

14.4 28 22 28 22 28 22

16.4 28 22 28 22 28 22

18.4 35 28 35 28 35 28

20.4 35 28 35 28 35 28

24.4 35 28 35 28 35 28

26.4 35 28 35 28 35 28

Diameter connection pipes between unit

and remote air coole condenser

4.9.8 Connection of Sigma 2002 LC/HP units to a remote air cooled condenser.

In motoevaporating units LC/HP during the winter operating mode (heat pump), the finned coil of the remote condenser operates as an evaporator; the refrigerant pipes connecting the remote condenser/evaporator will therefore need to have an increased diameter. If the remote condenser is supplied by Blue Box, the installer make the connection between the defrost temperature sensor terminals (inside the electric box) and the thermostat terminals inside the electric control box of the motoevaporating unit (see the electrical diagram). If the remote condenser is not supplied by Blue Box, the defrost is controlled only by the evaporating pressure (for more information see the paragraph “Defrost”) and there is not a temperature sensor on the remote condenser.

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TABLE 3 - CONNECTION PIPE EXTERNAL DIAMETERS FOR VERSIONS LC/HP

Distance between unit and remote condenser/evaporator [m]

10 20 30

MODEL

SIGMA 2002

LC/HP

Suction Liquid Suction Liquid Suction Liquid

[Delivery] [Suction] [Delivery] [Suction] [Delivery] [Suction]

[mm] [mm] [mm] [mm] [mm] [mm]

3.2 35 18 35 18 42 18

4.2 35 22 42 22 42 22

5.2 35 22 42 22 42 22

6.2 42 22 42 22 42 22

7.2 42 28 42 28 42 28

8.2 42 28 54 28 54 28

9.2 54 28 54 28 54 28

10.2 54 28 54 28 54 28

12.2 54 35 54 35 54 35

13.2 54 35 67 35 67 35

14.4 42 28 42 28 54 28

16.4 42 28 54 28 54 28

18.4 54 28 54 28 54 28

20.4 54 28 54 28 54 28

24.4 54 35 54 35 67 35

26.4 54 35 67 35 67 35

Diameter connection pipes between unit

and remote condenser/evaporator

4.10 PRESSURE RELIEF VALVES

Pressure relief valves are fitted on the high pressure side and low pressure side of the refrigerant circuit. The valves must be vented, to outdoors, through a vent pipe. The vent pipe must be sized no smaller than the relief valve and it must not be supported from the valve.

Caution: The relief valve must be directed into a safe zone where no injuries can be caused to people.

4.11 WATER QUALITY

When well or river water is applied for chilled water or condenser water, corrosion or debris problems may occur due to water quality. It is therefore necessary to analyse the quality of water by checking pH, electrical conductivity, ammonia ion content, sulphur and chloride content, total hardness, etc. and where necessary provide chemical treatment.

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4.12 LOW TEMPERATURE WATER AT CONDENSER

The units are not designed to operate with a condenser cooling water temperature below 20 °C. Below this limit, the unit could require substantial changes. Contact Blue Box for further information.

4.13 OPERATION WITH LOW TEMPERATURE CHILLED WATER AT EVAPORATOR

Standard units are not designed to operate with a water temperature below 5°C at the evaporator outlet. To operate below this limit, the unit will need to be modified. Contact Blue Box for further information.

If chilled water at the evaporator outlet is required below 5 °C, it is necessary to operate with a mixture of water and ethylene glycol. In this case, control and antifreeze set points must be changed. If low temperature is specified the set-points will be factory set.

The ethylene glycol percentage must be selected in relation to the required chilled water temperature (see Table

4).

TABLE 4 - FREEZING POINT FOR WATER-ANTIFREEZE MIXTURES

LIQUID OUTLET TEMPERATURE OR MINIMUM AMBIENT TEMPERATURE (°C) FREEZING POINT (°C) -5° -10° -15° -20° -25° -30° -35° -40° -45° ANTIFREEZE ETHYLENE GLYCOL 6 22 30 36 41 46 50 53 56 PROPYLENE GLYCOL 15 25 33 39 44 48 51 54 57 METHANOL 8 14 20 26 30 34 38 41 45 CALCIUM CHLORIDE 9 14 18 21 24 26 27 28 30 TEMPER -20 TEMPER -40 --TEMPER -60 TIFOXITE 50 60 63 69 73 --FREEZIUM 10 20 25 30 34 37 40 43 45 PEKASOL 50 59 68 75 81 86 90 ---

T -20°C

-20° -25° -30° -35°+0° -5° -10° -15°

% BY WEIGHT

---

T -40°C

T -60°C

-40°

If ambient temperatures lower than the freezing point of water can be expected, antifreeze mixtures in the percentages indicated in table 4 must be utilised.

If the glycol percentage is higher than 30%, units with special pump seals must be used.

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OPERATING LIMITS

SIGMA 2002 - Refrigerant R22 - R407C

Refrigeratore Chiller

Raffreddamento

Cooling

(1)

-5

-10

-10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60

(2)

Leaving chilled water temperature [°C]

Leaving condenser water temperature [°C]

55 50 45 40 35 30 25 20

(2)

Pompa di calore Heat pump

15 10

5 0

Leaving warm water temperature [°C]

-5

-10

-10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60

Raffreddamento

Cooling

(1)

(2)

Leaving source water temperature [°C]

The water temperature rise for all versions must be between 4 °C (min) and 7 °C (max) (1) Working limits of units with 2 compressors (2) Working limits of units with glycol and water mixture

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4.14 Water flow rate to evaporato and condenser

Perdite di carico [Kpa]

The nominal water flow rate given by Blue Box refers to a 5 °C temperature difference between inlet and outlet in relation to the rated cooling capacity. The maximum permissible flow rate is that which represents a temperature difference of 4 °C. Higher flow rates would lead to excessive pressure drops and could damage the heat exchanger. The minimum permissible flow rate is that which would result in a temperature difference of 7 °C or a pressure drop of no less than 10 kPa. Lower flow rates would lead to excessively low evaporation temperatures or to high condensing temperatures with consequent tripping of safety devices and shutdown of the unit.

4.15 EVAPORATOR CHILLED WATER TEMPERATURE

The minimum evaporator leaving water temperature is 5 °C: for lower temperatures refer to paragraph 4.12. The maximum water temperature at the evaporator inlet is 20 °C. In the case of higher temperatures specific solutions are necessary (dual circuits, three-way valves, by-pass, storage tanks)

CONDENSER PRESSURE DROP

100

90 80

70 60 50

Pressure drop

3.2

4.2

5.2

6.2

7.2

8.2

13.2

9.2

10.2

12.2

The water temperature rise for all versions must be between 4 °C (min) and 7 °C (max)

3 7 9

Portata acqua [l/s]

Water Flow

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8 10

12 14 16 18 20

Page 50

CONDENSER PRESSURE DROP

Portata acqua [l/s]

Perdita di carico [Kpa]

100

16.4

18.4

20.4

24.4

Pressure drop

26.4

14.4

6 8

7 11

Water Flow

1214161820 2522

The water temperature rise for all versions must be between 4 °C (min) and 7 °C (max)

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EVAPORATOR PRESSURE DROP

Portata acqua [l/s]

Perdita di carico [Kpa]

100

90 80

70 60 50

Pressure drop

Perdite di carico [Kpa]

3.2

4.2

5.2

6.2

7.2

8.2 9.2

10.2

12.2

13.2

100

90 80

Pressure drop

Portata acqua [l/s]

Water Flow

14.4

10 12 14 16 18 20

16.4

18.4

20.4

24.4

26.4

The water temperature rise for all versions must be between 3 °C (min) and 8 °C (max)

6 8

Water Flow

1214161820 2522

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4.16 ELECTRICAL CONNECTIONS

4.16.1 General

Electrical connections must be made in accordance with the information given on the electrical drawing attached to the unit and in compliance with the applicable local regulations.

An Earth (ground) connection is compulsory. The installer must connect the earth cable with a dedicated terminal on the earth bar in the electrical board (refer to the illustration on the following page) labelled PE.

It must be verified that the electrical supply corresponds to the unit electrical nominal data (tension, phases, frequency) indicated on the label on the front panel of the unit.

Line voltage fluctuations must not be more than ±5% of the nominal value, while the voltage unbalance between one phase and another must not exceed 2%. If these tolerances are not possible contact Blue Box to provide the necessary devices.

Check that the line is connected with the correct phase sequence. Cable power inlet into the electric panel:

- Models from 3.2 to 13.2, from the left side of electric panel.

- Models from 14.4 to 26.4, from the top of electric panel The control circuit is derived from the power supply through a transformer located inside the electrical panel. The control circuit is protected by fuses.

Electrical cable anchorage: anchor the electrical power cables with fixing systems able to withstand pulling and torsional stress.

Before any operation on the electrical section, be sure that the electric supply is disconnected.

Power cable and line protection must be sized according to the specification indicated on the wiring diagram and the documents supplied with the unit.

The crankcase heaters must be connected at least 12 hours before starting the unit; the heaters are automatically connected when the main disconnect switch is set to the ON position.

The electrical supply must be within the limits shown. If this is not the case the warranty will be terminated immediately.

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4.16.2 Power supply to crankcase heaters

1) Close the main disconnect switch by turning it from position "0" to position "1"

2) Check that the word "OFF" is shown on the display

3) Ensure that the unit is in "OFF" status and that the external enabling contact is open

4) After a few moments, if the phase sequence is incorrect the alarm "INCORRECT PHASE SEQUENCE" will be displayed (4-compressor models from 14.4 to 26.4 only, with pCO2 controller). In this case invert the connections of two of the power line phase wires.

5) Leave the unit in this condition for at least 12 hours to allow the crankcase heaters to perform their function

4.16.3 Potential free contacts

The following potential free contacts are available:

- 1 potential free contact for general alarm (terminals 100 - 101 - 102)

- 1 potential free contact for each compressor (option)

4.16.4 Flow switch electrical connections

Flow switch electrical connections (see paragraph 4.5 ) must be connected to terminal 1-14 for chiller units. For heat pump units evaporator (user exchanger) flow switch must be connected to terminals 1-15 while condenser (source exchanger) flow switch must be connected to terminals 14-15.

4.16.5 Circulating pump electrical connections

The external interlocks of unit must close for the unit to operate. The normally open external water circulating pump contactor terminals must be wired in series with terminals 1 and 2, on the unit control panel, to ensure that the chiller can only start after the pump is in operation.

Turn on the pump before the unit starts and stop it after the unit has stopped (recommended time delay: 60 sec).

4.16.6 External interlock

If a remote ON-OFF is required connect the external interlock to terminals 1 and 2. If an external interlock is not required, bridge therminals 1 and 2 to enable the unit to start.

4.17 MICROPROCESSOR CONTROLLERS

Chillers in the SIGMA 2002 series with 2 scroll compressors, models from 3.2 to 13.2, are equipped with the mCHILLER type microprocessor controller.

Chillers in the SIGMA 2002 series with 4 scroll compressors, models from 14.4 to 26.4, are equipped with the pCO2 microprocessor controller.

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4.17.1 Microprocessor controller for /LE and HP/LE versions

- Versions SIGMA 2002 /LE and SIGMA 2002 HP/LE with two compressors are equipped with an mCHILLER

controller.

- Versions SIGMA 2002 /LE and SIGMA 2002 HP/LE with four compressors do not have an integral controller and therefore an external controller, or thermostats, must be connected to the auxiliary terminals 1-21, 1-31, 1-41 and 1-51.

Consult the electrical diagram attached to the unit.

4.17.2 RS485 serial interface (optional)

All units can be equipped with a serial interface board for supervision or remote diagnostic functions via a computer.

The serial interface board plugs into a dedicated slot on the connection board. Connection to the supervision or remote diagnostics serial line is executed in compliance with standard RS485 and is achieved by means of the serial interface boards.

Models from 3.2 to 13.2 with two scroll compressors and mCHILLER controller

When the serial interface board is inserted the Carel communications protocol is available. A conversion gateway is required for Modbus-jbus and BacNet protocols.

Models from 14.4 to 26.4 with four scroll compressors and pCO2 controller

When the serial interface board is inserted the following communications protocols are available: Carel, Modbusjbus, BacNet. If a connection is to be made with networks that utilise the Lon-Talk protocol, a dedicated board must be installed. In this case, a conversion gateway is not required.

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ELECTRIC PANEL LAY OUT

SIGMA 2002 - SIGMA 2002 HP - SIGMA 2002 LE - SIGMA 2002 LE/HP - SIGMA 2002 LC SIGMA 2002 LC/HP - Models 3.2 - 13.2

Models 3.2 - 10.2

KM1 CONTACTOR COMPRESSOR 1 KM2 CONTACTOR COMPRESSOR 2 KM41 CONTACT. CAPACITOR POW. FACT. CORRECT. 1 KM42 CONTACT. CAPACITOR POW. FACT. CORRECT. 2 FU1 FUSES COMPRESSOR 1 FU2 FUSES COMPRESSOR 2 QS1 MAIN SWITCH FU41 FUSES CAPACITOR POW. FACT. CORRECT. 1 FU42 FUSES CAPACITOR POW. FACT. CORRECT. 2 FU56 PHASE SEQ. RELAY FUSES FU50 FUSES AUX. TRANSFORMER FU51 AUX. CIRCUIT FUSES FU52 FUSE CONTROL KA5 PHASE SEQUENCE RELAY TC1 AUX. TRANSFORMER KA1 VOLTAGE RELAY

OPTIONAL

Models 12.2 - 13.2

KM1 CONTACTOR COMPRESSOR 1 KM2 CONTACTOR COMPRESSOR 2 KM41 CONTACT. CAPACITOR POW. FACT. CORRECT. 1 KM42 CONTACT. CAPACITOR POW. FACT. CORRECT. 2 FU41 FUSES CAPACITOR POW. FACT. CORRECT. 1 FU42 FUSES CAPACITOR POW. FACT. CORRECT. 2 FU56 PHASE SEQ. RELAY FUSES FU50 FUSES AUX. TRANSFORMER FU51 AUX. CIRCUIT FUSES FU52 FUSE CONTROL KA5 PHASE SEQUENCE RELAY KA1 VOLTAGE RELAY FU1 FUSES COMPRESSOR 1 FU2 FUSES COMPRESSOR 2 QS1 MAIN SWITCH TC1 AUX. TRANSFORMER

OPTIONAL

A4 BOARD FOR REMOTE CONTROL A2 CONTROL BOARD A3 EXPANSION BOARD 2 COMPRESSORB

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ELECTRIC PANEL LAY OUT

SIGMA 2002 - SIGMA 2002 HP - SIGMA 2002 LE - SIGMA 2002 LE/HP - SIGMA 2002 LC SIGMA 2002 LC/HP - Models 14.4 - 26.4

KM1 CONTACTOR COMPRESSOR 1 KM2 CONTACTOR COMPRESSOR 2 KM3 CONTACTOR COMPRESSOR 3 KM4 CONTACTOR COMPRESSOR 4 A13 TERMOSTATO BATTERIA FU1 FUSES COMPRESSOR 1 FU2 FUSES COMPRESSOR 2 FU3 FUSES COMPRESSOR 3 FU4 FUSES COMPRESSOR 4 QS1 MAIN SWITCH FU56 PHASE SEQ. RELAY FUSES FU50 FUSES AUX. TRANSFORMER FU52 FUSE CONTROL TC1 AUX. TRANSFORMER A5 PHASE SEQUENCE RELAY FU51 AUX. CIRCUIT FUSES

OPTIONAL

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ELECTRIC PANEL LAY OUT

SIGMA 2002 - SIGMA 2002 HP - SIGMA 2002 LE - SIGMA 2002 LE/HP - SIGMA 2002 LC SIGMA 2002 LC/HP - Models 14.4 - 26.4

SIGMA 2002 LC - SIGMA 2002 LC/HP - WITH ARRANGEMENT FOR REMOTE CONDENSER

KM41 CONTACT. CAPACITOR POW. FACT. CORRECT. 1 KM42 CONTACT. CAPACITOR POW. FACT. CORRECT. 2 KM43 CONTACT. CAPACITOR POW. FACT. CORRECT 3 KM44 CONTACT. CAPACITOR POW. FACT. CORRECT 4 FU41 FUSES CAPACITOR POW. FACT. CORRECT. 1 FU42 FUSES CAPACITOR POW. FACT. CORRECT. 2 FU43 FUSES CAPACITOR POW. FACT. CORRECT. 3 FU44 FUSES CAPACITOR POW. FACT. CORRECT. 4

SIGMA 2002 LC - SIGMA 2002 LC/HP - WITH ARRANGEMENT FOR REMOTE CONDENSER

KM21 CONTACTOR FAN 1 KM22 CONTACTOR FAN 2 KM23 CONTACTOR FAN 1 HP KM24 CONTACTOR FAN 2 HP FU21 FUSES FANS 1 FU22 FUSES FANS 2 FU20 FUSES FAN SPEED CONTROL

WITH REMOTE CONDENSER

PANEL LOGIC SECTION WITH CONTROL

A2 CONTROL BOARD A3 EXPANSION BOARD 2 COMPRESSORS

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ELECTRIC PANEL LAY OUT

SIGMA 2002 LC - SIGMA 2002 LC/HP - WITH ARRANGEMENT FOR REMOTE CONDENSER AND POWER FACTOR CORRECTION CONDENSERS - Models 3.2 - 7.2

KM1 CONTACTOR COMPRESSOR 1 KM2 CONTACTOR COMPRESSOR 2 KM21 CONTACTOR FAN 1 KM23 CONTACTOR FAN 2 FU1 FUSES COMPRESSOR 1 FU2 FUSES COMPRESSOR 2 KM41 CONTACT. CAPACITOR POW. FACT. CORRECT. 1 KM42 CONTACT. CAPACITOR POW. FACT. CORRECT. 2 FU20 FUSES FAN SPEED CONTROL FU21 FUSES FAN 1 FU56 PHASE SEQ. RELAY FUSES FU50 FUSES AUX. TRANSFORMER FU51 AUX. CIRCUIT FUSES FU52 FUSE CONTROL KA5 PHASE SEQUENCE RELAY QS1 MAIN SWITCH FU41 FUSES CAPACITOR POW. FACT. CORRECT. 1 FU42 FUSES CAPACITOR POW. FACT. CORRECT. 2

PANEL LOGIC SECTION WITH CONTROL

OPTIONAL

KA1 VOLTAGE RELAY KA2 RELAY ALARM FANS KA3 RELAY HP/LC KA31 RELAY HP 1 A4 BOARD FOR REMOTE CONTROL A2 CONTROL BOARD A3 EXPANSION BOARD 2 COMPR. A13 THERMOSTAT COIL A10 CONTROL BOARD ON/OFF

OPTIONAL

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ELECTRIC PANEL LAY OUT

SIGMA 2002 LC - SIGMA 2002 LC/HP - Models 8.2 - 12.2

KM1 CONTACTOR COMPRESSOR 1 KM2 CONTACTOR COMPRESSOR 2 KM21 CONTACTOR FAN 1 KM23 CONTACTOR FAN 1 HP FU1 FUSES COMPRESSOR 1 FU2 FUSES COMPRESSOR 2 FU20 FUSES FAN SPEED CONTROL FU21 FUSES FAN 1 FU56 PHASE SEQ. RELAY FUSES FU50 FUSES AUX. TRANSFORMER FU51 AUX. CIRCUIT FUSES FU52 FUSE CONTROL KA5 PHASE SEQUENCE RELAY TC1 AUX. TRANSFORMER QS1 MAIN SWITCH

PANEL LOGIC SECTION WITH CONTROL

OPTIONAL

KA1 VOLTAGE RELAY KA2 RELAY ALARM FANS KA3 RELAY HP/LC KA31 RELAY HP 1 A4 BOARD FOR REMOTE CONTROL A2 CONTROL BOARD A3 EXPANSION BOARD 2 COMPR. A13 THERMOSTAT COIL A10 CONTROL BOARD ON/OFF

OPTIONAL

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ELECTRIC PANEL LAY OUT

SIGMA 2002 LC - SIGMA 2002 LC/HP - WITH ARRANGEMENT FOR REMOTE CONDENSER AND POWER FACTOR CORRECTION CONDENSERS - Models 8.2 - 13.2

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ELECTRIC PANEL LAY OUT

SIGMA 2002 LC - SIGMA 2002 LC/HP - WITH ARRANGEMENT FOR REMOTE CONDENSER AND POWER FACTOR CORRECTION CONDENSERS - Models 8.2 - 13.2

KA1 VOLTAGE RELAY KA2 RELAY ALARM FAN KA3 RELAY HP/LC KA31 RELAY HP 1 KM1 CONTACTOR COMPRESSOR 1 KM2 CONTACTOR COMPRESSOR 2 KM21 CONTACTOR FAN 1 KM22 CONTACTOR FAN 2 KM23 CONTACTOR FAN 3 KM24 CONTACTOR FAN 4 KM41 CONTACT. CAPACITOR POW. FACT. CORRECT. 1 KM42 CONTACT. CAPACITOR POW. FACT. CORRECT. 2 FU1 FUSES COMPRESSOR 1 FU2 FUSES COMPRESSOR 2 FU20 FUSES FAN SPEED CONTROL FU21 FUSES FAN 1 FU22 FUSES FAN 2 FU41 FUSES CAPACITOR POW. FACT. CORRECT. 1 FU42 FUSES CAPACITOR POW. FACT. CORRECT. 2 A10 CONTROL BOARD ON/OFF A13 THERMOSTAT COIL FU50 FUSES AUX. TRANSFORMER FU51 AUX. CIRCUIT FUSES FU52 FUSE CONTROL FU56 PHASE SEQ. RELAY FUSES TC1 AUX. TRANSFORMER A5 PHASE SEQUENCE RELAY

OPTIONAL

PANEL LOGIC SECTION WITH CONTROL

A4 BOARD FOR REMOTE CONTROL A2 CONTROL BOARD A3 EXPANSION BOARD 2 COMPRESSORS

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5. START-UP

5.1 PRELIMINARY CHECKS

- Check that the electrical connections have been made correctly, and that all terminals are tight.

- Check that the voltage on the RST terminals is 400 V ± 5% (or the unit’s rated value, in the event of units supplied to run on non-standard power supplies). If the mains voltage is subject to frequent fluctuations, consult our Engineering Department to discuss the necessary protection systems.

- Check that the display shows the gas pressure in the refrigerant circuit (4-compressor models only).

- Inspect the unit for refrigerant leaks using a leak detector if necessary.

- Check that the crankcase heaters are correctly supplied with power.

- Verify that the heaters are working correctly. After the warm up period the crankcase must be warm to the touch and be at a temperature of at least 10 to 15 °C higher than the ambient temperature.

- Check that all hydraulic connections are correctly installed and all indications on the unit labels are observed.

- Check that the hydraulic system has been vented to eliminate any air remaining. Fill the system gradually and open the vent devices on the higher sections. The installer must provide a correctly sized expansion device.

Significant leakage of R407C refrigerant, in a gaseous state, will alter the percentages of the remaining mixture with a consequent reduction in performance.

The heaters must be connected at least 12 hours before starting the unit. The heaters are automatically connected when the main disconnect switch is set to the ON position.

Warning: before starting the unit check that all the enclosure panels are in position and secured with the relative screws.

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Models 3.2 - 13.2, controller µchiller

6 UNIT WITH mCHILLER MICROPROCESSOR (models from 3.2 to 13.2)

6.1 INTRODUCTION

“mCHILLER” is an electronic microprocessor system designed to control all the unit’s functions. The terminal is equipped with five LEDs indicating the operating status of the machine (summer/winter), the compressor status (On/Off) and indication of the compressors/pump hour counter after the first 100 hours of operation. An internal beeper (which can be inhibited by means of a microswitch or a parameter) sounds to warn of machine operating anomalies.

6.1.1 Display

The display comprises three digits with automatic display of the decimal point. During normal operation the display shows the value of the evaporator inlet water temperature. “mCHILLER” can be connected to a computer, by means of an optional electronic board, making available remote supervision and telediagnostic services for complete management, supervision and diagnostics of the systems from a remote location.

Figure 15

6.1.2 Machine status information

Machine status information is shown by five LEDs on the remote control display (figure 16).

Figure 16

6.1.3 Keypad

The keypad allows machine operating parameters to be programmed. The wall-mounted version features an extended number of keys to facilitate use. The function of each key is illustrated on the following pages.

Figure 17

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Models 3.2 - 13.2, controller µchiller

6.1.4 Control and display screens

Method of accessing the set-point and main machine control parameters.

Parameter scroll keys

Figure 18

Pressing the keys marked with an up or down arrow allows you to scroll through the parameters. The SEL key is pressed again to display the value of the selected parameter, with the facility to edit the value if required using the Up or Down keys. The PRG key is pressed to store changed values and to stop the procedure, while pressing the SEL key returns you to the parameter selection menu. If no keys are pressed, in an interval of 10 seconds, during parameter editing the display starts flashing. If no keys have been pressed within 60 seconds, after activating the programming procedure, the controller will return to the temperature display without saving any changes that have been made. This procedure is useful if it proves unnecessary to alter any parameters.

6.1.5 Muting the BUZZER

Press the MUTE key to silence the buzzer if it is currently sounding.

Figure 19

6.1.6 ALARMS reset

Pressing the Up or Down keys for more than 5 seconds cancels any alarms currently in the memory (manual reset), clear the associated message from the display and deactivate the alarm relay. In wall mounted models this function is obtained by pressing the CLEAR key for 5 seconds.

Figure 20

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Models 3.2 - 13.2, controller µchiller

6.1.7 Activation/deactivation of COOLING operation (summer mode)

Pressing the key for more than 5 seconds activates or deactivates the summer operating mode (refer also to parameter P6). It is not possible to switch directly from Winter mode to Summer mode without first deactivating Winter mode. If the machine was previously running in Winter mode pressing this key will have no effect.

Figure 21

6.1.8 Activation/deactivation of HEATING mode (winter mode)

Pressing the key for more than 5 seconds activates or deactivates the winter operating mode. It is not possible to switch directly from Summer mode to Winter mode. If the machine was previously running in Summer mode pressing this key will have no effect - Summer mode must be deactivated before the change can be made.

Figure 22

6.1.9 Switching off the machine (stand by)

To switch off the machine deactivate both Summer and Winter modes.

Switch off the unit when working in cooling mode (Summer).

Figure 23

Switch off the unit when working in heating mode (Winter).

Figure 24

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Models 3.2 - 13.2, controller µchiller

6.1.10 Inlet water temperature control:

To edit the operating values (within the operating limits) hold down the SEL button for 5 seconds. When it flashes use the Up or Down arrow keys to enter the required inlet water temperature on the display. Confirm the value you have just entered by pressing the SEL button again (figure 25).

Parameter scroll keys

Figure 25

6.1.11 Defrosting ( only /LC/HP, heat pump units)

During winter mode operation (heat pump) the the remote condenser finned coil functions as an evaporator, cooling and dehumidifying ambient air. During heat pump operation, the evaporation pressure is monitored to prevent it from falling below a preset value. The evaporation control is active only during heating mode operation. Depending on the ambient air temperature and humidity conditions, condensate or frost will tend to form, consequently obstructing the free passage of air and causing thermal insulation. The frost that builds up on the coil obstructs the passage of air, reduces the available heat exchange surface area (and thus the thermal efficiency), and can damage the exchanger. Defrosting is the procedure that serves to prevent or eliminate the formation of ice on the evaporator coil during heat pump mode operation of an air to water unit. Defrosting is performed simultaneously for the entire unit. All heat pump versions are equipped with a control that activates an automatic coil defrost cycle when necessary. After starting however, the first defrost cycle will be started after a preset minimum operating time to allow the formation of sufficient thermal inertia to allow the cycle to be completed successfully. Defrost cycle demands are based on detection of a low suction pressure value, due to the insufficient heat exchange between the evaporator and the air because of the formation of a layer of ice, which exerts a thermal insulation effect. For a defrost cycle to be able to start the suction pressure of at least one of the currently operating compressors must remain below the pressure set for the defrost cycle trip signal for a given time interval. Before starting to defrost the coils, all the compressors are started, after which the unit is switched from heat pump to cooling mode. When the cycle is reversed the fans stop and the compressors force hot gas into the coil. A pressure switch on the high pressure circuit maintains the gas discharge pressure below the defrost end value. To maintain the pressure lower than the defrost end pressure the pressure switch activates the fans. To reduce the air flow, and obtain more efficient heating of the outer part of the coil, the pressure switch signal causes the fans to rotate in reverse. On remote condensers/evaporators supplied by Blue Box when the defrost end temperature is reached, as measured by a thermostat with the relative sensor located in the lower part of the coil, the pressure switch allows the delivery pressure to reach the defrost end pressure. With remote condensers/evaporators not supplied by Blue Box the heat exchanger is controlled by pressure only. When the defrost end pressure has been reached the controller reverses the unit from chiller mode to heat pump mode thereby terminating the defrost procedure. Even though in certain conditions the surface temperature of the coil and the condensation pressure fail to reach the defrost values, within the preset time limit, the defrost cycle is forcibly terminated as though the defrost end signal were present. The controller restarts the fans and when the pressure returns to the preset value it reverses the unit’s operating mode again. If the defrost cycle is forcibly interrupted with the timeout signal it is signalled on the display even though no

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Models 3.2 - 13.2, controller µchiller

controller functions are activated. The defrost timeout alarm is automatically cleared from the active alarms menus when a defrost cycle terminates normally because the defrost end pressure has been reached. In any event, the alarms historical file will contain a record of all defrost cycles that were terminated forcibly due to a timeout intervention. Consecutive defrost cycles must be at least 30 minutes apart. If a forced defrost signal persists inform the Service organisation.

If the unit fails to start:

do not change internal electrical connections on penalty of immediate invalidation of the warranty.

Warning: The operating mode changeover should only be seasonal. Frequent changeover from summer to winter operating mode and viceversa could cause damage to the compressors.

During idle periods do not disconnect the unit from the power supply (the compressor crankcase heaters must remain switched on in these intervals). Disconnect the unit from the power supply only in the event of prolonged disuse (e.g. seasonal shutdowns). For temporary shutdown of the unit refer to the guide lines given in paragraph 6.3.1.

Electronic components of the microprocessor may be damaged at temperatures below - 20 °C.

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Models 3.2 - 13.2, controller µchiller

6.2 STARTING THE UNIT

The SIGMA 2002 unit is equipped, as standard, with direct keypad control. Optionally the unit can be equipped to operate via a remote permissive (e.g. a clock, etc.). The remote interlock must be connected across terminals 1-2. Enabling the unit to start or stop is only possible via the keypad.

6.2.1 COOLING:

- Press the button as shown in figure 26.

Figure 26

6.2.2 HEATING (operation in heat pump mode):

- Press the button as shown in figure 27.

Figure 27

6.3 STOPPING THE UNIT

6.3.1 Temporary stop

The unit is stopped by pressing the cooling key or, in the case of a heat pump unit operating in winter mode, by pressing the heating key.

Shutdown of unit operating in summer cooling mode

Figure 28

Shutdown of unit operating in winter heating mode

Figure 29

Warning: do not use the machine main power switch to stop the unit. The crankcase heaters will be disconnected, resulting in serious risk to the compressors when the unit is started again.

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Models 3.2 - 13.2, controller µchiller

6.3.2 Seasonal stop:

- Disconnect the power supply

- Drain the system circuit (unless it contains a water/glycol solution)

- When the unit is to be restarted repeat the initial start-up procedure

Warning: do not use the machine main power switch to stop the unit:

6.4 EMERGENCY STOP

Emergency stops are obtained by turning the red colour main disconnect switch on the electrical panel to position

this switch must be used to disconnect the electrical supply when no current is flowing on the circuit, i.e. only when the unit is in OFF status. Note also that if power is disconnected from the unit the crankcase heaters will be switched off with the resulting risk of compressor damage at the time of restarting.

7. TROUBLESHOOTING

The following pages contain a list of the most common causes that can result in the shutdown or anomalous operation of the chiller. Faults are arranged in accordance with easily identifiable symptoms.

In relation to possible corrective action pay maximum attention to the operations you intend to perform as overconfidence coupled with insufficient attention due to lack of expertise can lead to serious accidents. We therefore recommend that Blue Box or other skilled HVAC engineers are contacted to identify and correct the problem.

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Models 3.2 - 13.2, controller µchiller

SYMPTOM

A) No compressor running. (display off)

B) No compressor running. (display on, no alarm messages)

OPERATION

COOLING

⊗ ⊗

HEATING

PROBABLE CAUSE

POSSIBLE CORRECTIVE ACTION

No mains power Check presence of mains power

Main power switch Off (position "O")

Turn mains power selector to position "I"

No power to control circuits Check condition of fuses FU50,

FU51, FU52. Check operation of the transformer

Incorrect phase sequence (relay KA5 with only green LED lit)

Invert two of the phase wires of the power feeding line; when the unit is powered up again both the green LED and the yellow LED should light

Relay KA5 with green and yellow LEDs off

Check fuses FU56; If fuses are OK replace phase sequence relay

Unit in stand-by mode Start unit (see relative section of

the manual)

No consent from service thermostat

System at set-point temperature, no heating/cooling demand; check settings and operation.

No external consent Check operation of circulator

pumps, flow switches, bleed air from the system; check that contacts 1 and 2 are closed, check other external consents.

Compressor motor burnt

Replace compressor

out or compressor seized

Anti-recycle timer running Wait for 5 minutes until the

timer generates a consent

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Models 3.2 - 13.2, controller µchiller

SYMPTOM

C) No compressor

running. (display On with alarm "FL")

No compressor

running. Fans stopped

(display On with alarm

“F1” or “F2”)

(only version LC and

LC/HP)

No compressor

running. (display On

with alarm "A1")

No compressor

running. (display On,

with alarm "E1")

OPERATION

COOLING

⊗ ⊗

HEATING

PROBABLE CAUSE

POSSIBLE CORRECTIVE ACTION

No water flow at

Check hydraulic system

evaporator

Faulty flow switch Check contact of flow switch

and replace if necessary

Fan thermal protection intervention

Check insulation between windings and between windings and earth; replace fan if necessary.

No consent of defrost thermostat due to insufficient water flow rate

Check hydraulic circuit and wait until the water temperature exceeds the value necessary for the unit to restart

No consent of defrost thermostat due to insufficient glycol concentration

The programmed set-point is too low for the percentage of glycol in the circuit. Increase the glycol percentage and reduce the defrost set-point.

Connections to evaporator inlet temperature sensor

Restore correct connection of temperature sensor

interrupted

Evaporator inlet

Replace temperature sensor

temperature sensor faulty

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Page 72

Models 3.2 - 13.2, controller µchiller

SYMPTOM

G) No compressor running. (display On, with alarm "E3" or "E5")

H) Unit runs with insufficient capacity (Display On without alarms)

OPERATION

COOLING

⊗ ⊗

⊗

HEATING

PROBABLE CAUSE

Resistance RK3 or RK4 faulty or disconnected (only version LC and LC/HP)

Connections to pressure sensor interrupted (HP version only or if condensation pressure control with fan speed regulator is fitted with version LC and LC/HP)

Faulty pressure sensor (only on HP version or if condensation pressure control with fan speed regulator is fitted with version LC and LC/HP)

Insufficient refrigerant charge

Presence of moisture in refrigerant circuit

One compressor fails to start, power circuit open and compressor contactor energised

A compressor fails to start, fuses are OK and compressor contactor is deenergised

4-way reversing valve locked or coil faulty

POSSIBLE CORRECTIVE ACTION

Check resistance and replace if necessary

Restore correct connections to pressure sensor ("E3" refers to compressor 1, "E5" refers to compressor 2)

Replace pressure sensor ("E3" refers to compressor 1, "E5" refers to compressor 2)

Check refrigerant circuits with leak detector, repair leak and recharge circuit

Replace refrigerant filter and, if necessary, dehydrate and recharge circuit

Find and eliminate the cause of the protection intervention; change the fuses. If the fuses blow immediately, replace the compressor.

Check voltage across compressor contactor coil and continuity of coil; if necessary, replace coil

Check power supply and coils of valves and replace valves if necessary

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Page 73

Models 3.2 - 13.2, controller µchiller

SYMPTOM

Compressor 1 and/or 2

not working (display

On with alarm

“H1” and/or “H2”)

OPERATION

COOLING

⊗ ⊗

PROBABLE CAUSE

HEATING

Circuit overcharged (only version LC and LC/HP)

⊗ ⊗

High pressure switch faulty Check and replace if necessary

Coil filters clogged; air flow too low (version LC and LC/HP)

⊗ ⊗

Presence of incondensable gas in the refrigerant circuit

⊗ ⊗

Fans faulty (version LC and LC/HP)

⊗ ⊗

Faulty circulating pump Check and replace

⊗

Defrost-end pressure switch not working (only version LC/HP)

⊗ ⊗

Metallic filter of condenser clogged

⊗ ⊗

Insufficient condenser water flow

⊗ ⊗

Condenser entering water temperature too high

POSSIBLE CORRECTIVE ACTION

Check refrigerant charge and remove if necessary;

Clean filters with compressed air

Empty circuit, apply vacuum, and recharge

Check and replace fans

Check and replace

Clean filter

Check hydraulic circuit and condenser water flow

Check condenser hydraulic circuit

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Page 74

Models 3.2 - 13.2, controller µchiller

SYMPTOM

L) Compressor 1 and/or 2 not working (display On with alarm “L1” and/or “L2”)

OPERATION

COOLING

⊗ ⊗

PROBABLE CAUSE

HEATING

Refrigerant circuit completely empty

⊗ ⊗

⊗

Low pressure switch faulty Check and replace if necessary

Metallic coil filter clogged; air flow too low (only LC/HP)

⊗ ⊗

Refrigerant filter clogged Check and replace if necessary

⊗ ⊗

Faulty water circulator pump

⊗

Defrost pressure switch with incorrect setting (only version LC/HP)

⊗ ⊗

Liquid refrigerant valve not completely open (if present)

⊗ ⊗

Thermostatic expansion valve not operating correctly

⊗ ⊗

Evaporator metallic filter clogged

⊗ ⊗

Evaporator circulating pump faulty

POSSIBLE CORRECTIVE ACTION

Check refrigerant circuit with leak detector after pressurising to approximately 4 bar. Repair leak, apply vacuum, charge circuit.

Clean filter with compressed air

Check and replace if necessary

Check and correct setting

Check and open fully

Check, clean, or replace if necessary

Clean the filter

Check, and replace if necessary

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Models 3.2 - 13.2, controller µchiller

SYMPTOM

M) Compressor 1 and/or 2 not working (display On with alarm “C1” and/or “C2”)

N) Ice on liquid refrigerant pipe

O) Compressors run constantly

OPERATION

COOLING

⊗ ⊗

⊗

⊗ ⊗

HEATING

PROBABLE CAUSE

POSSIBLE CORRECTIVE ACTION

Insufficient refrigerant charge

Find leak with leak detector, repair, and recharge circuit

4-way valve locked Replace valve

Lack of oil Check quantity of oil in circuit

and replenish as necessary. Check that the circuit has all the necessary measures to ensure oil return to the compressor

Condenser entering water temperature too high

Check temperature and flow of condenser entering water

Liquid refrigerant filter

Replace filter

clogged

Valve on liquid refrigerant

Open valve fully line (if present) not completely open

Operating thermostat incorrectly set or faulty

Check setting; replace

thermostat if necessary

Lack of refrigerant gas

Check and recharge if necessary charge

Excess thermal load Reduce thermal load

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Models 3.2 - 13.2, controller µchiller

SYMPTOM

P) Anomalous noise from

system

OPERATION

COOLING

⊗ ⊗

HEATING

PROBABLE CAUSE

POSSIBLE CORRECTIVE ACTION

Compressor noisy Contact service organisation for

check and replacement if necessary

Thermostatic valve noisy Contact service organisation for

check and replenish refrigerant charge

Vibrating pipes Contact service organisation to

secure pipelines

Casing panels vibrate Check that panels are properly

fastened; contact service organisation if necessary

If the display presents alarms other than those described previously, contact the Service organisation.

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Page 77

Models 14.4 - 26.4, controller pCO

8 UNIT WITH pCO2 MICROPROCESSOR (models from 14.4 to 26.4)

8.1 GENERAL

The pCO2 electronic microprocessor controller with the DBBB0*P20Z program is designed to manage chiller and heat pump units, with control of 4 compressors. The program provides the facility to control water-cooled units with plate heat exchangers and to manage compressor start and stop times, safety devices and auxiliary functions including condensation control in cooling mode, heat recovery functions, and other functions described later in this manual. The necessary hardware is optimised to obtain the maximum advantage from the available inputs and outputs; the connection between various circuit boards and the user interface terminal is achieved via the pLANE using the dedicated RS485 serial connector for network connections. Each unit can also be connected to remote supervision and/or telediagnostics systems by means of an RS485 serial line.

Detailed information on the operation of the above systems is provided in the specific controller manual supplied with the unit.

8.1.1 Display

The back-lit LCD display comprises 4 lines and 20 columns.

Figure 30

8.1.2 Keypad

In addition to the LCD display, the user interface is equipped with the following function keys:

“Menu” key: press this key from any menu to return to the opening menu.

Maintenance key: press this key to access the maintenance menus.

Print key: this key is currently not used.

"I/O" key: pressing this key opens the menus containing the status of the digital inputs and outputs together with the values read on the analogue inputs and the value of the analogue outputs

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Models 14.4 - 26.4, controller pCO

“Clock” key: press this key to open the clock menus.

“Set” key: this key opens the menus in which the various operating set-points can be edited.

“Prog” key: this key opens the service menus.

"? info" key: pressing this key opens a menu in which the address of the component connected to the terminal can be changed.

"Summer" key (blue) and "winter" key (red): in the case of chiller + heat-pump units, press these keys to select the required operating mode.

“ON/OFF” key: press this key to switch from Stand- by to ON or vice versa.

“Alarm” key: this key serves to mute the alarm buzzer, display any active alarms, and reset them in certain cases.

Arrow key: the arrow keys allow you to navigate through the menus; when an editable field is selected, the arrow keys serve to change the current value.

“Enter” key: pressing this key allows you to access fields containing editable parameters and also to confirm any changes you make to such parameters.

Electronic components could be damaged by air temperature below -20 °C.

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Models 14.4 - 26.4, controller pCO

8.2 OPERATING DESCRIPTION

8.2.1 Introduction

The microprocessor control regulates the water temperature of the evaporator maintaining it at the set-point value acting on the compressors management. The control manages all the components of the chiller, the alarms and “ancillary” functions.

Almost all the parameters referred to below (set-points, differentials, calibration, delays...) can be programmed by means of the various menus. Refer to the specific manual for the pCO2 controller.

8.2.2 Unit in stand-by mode

The unit is in stand-by mode when it is correctly supplied with power but not actually enabled to operate. In this condition the display shows the values of the various machine parameters, but the operation of the compressor is not inhibited. Power-on is obtained by pressing the “ON-OFF” button of the microprocessor control or via an external interlock.

8.2.3 Enabling the unit

Start-up of the unit from stand-by mode can be achieved after closing the external enabling contact, by pressing the "ON/OFF" button, or by means of a signal on the serial line. Activation of the controller outputs that manage the various sections of the chiller is executed in strict compliance with the operating times. If the "ON" button is pressed before the external interlocks are closed, the display indicates which of the external interlocks is not yet enabled. Operation of the pump has priority to the compressors, which can start only after the evaporator and condenser pumps are running.

8.2.4 Pumps management

The microprocessor controller does not manage the operation of chilled water and condenser pumps. When the unit is switched from normal operation to stand-by, due to the opening of an external interlock, the active pump must be stopped with a delay following the stopping of the last active compressor, to benefit from the thermal inertia of the system.

8.2.5 Compressor start-up

The controller allows the compressors to be started if the flow switch input is closed within the compressor startup delay time interval. If the flow switch input opens, after the compressor has started, the trip is retarded if it occurs within the time programmed for the compressor stop. If the unit trips due to the opening of the flow switch input, the relative alarm is displayed. Starting and stopping of the compressors and capacity step control is managed by the controller in accordance with the building cooling demands.

8.2.6 Chiller mode operation

In chiller operation, the controller lowers the water temperature value, maintaining it as close as possible to the programmed set-point. In the standard version, in which the control acts on the evaporator entering water, the management of compressor operation and capacity steps is linked to the difference between the entering water temperature and the programmed set-point.

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Models 14.4 - 26.4, controller pCO

8.2.7 Heat pump mode operation

In heat pump operation, the controller increases the water temperature value, maintaining it as close as possible to the programmed set-point. Management of compressor operation is performed in the same way as already illustrated for chiller mode operation.

8.2.8 Evaporator low temperature chilled water protection

If the evaporator leaving water temperature is lower than the limit value programmed in the low temperature chilled water protection set-point, the controller will stop all the compressors and activate the low temperature water alarm. This alarm must be reset manually and the compressor restarted only when the evaporator leaving water temperature is equal to or higher than the alarm trip value, increased by the low temperature water differential. The low temperature water alarm can only appear when the unit is switched on (in stand-by conditions the freeze alarm is not operational).

8.2.9 Evaporator anti-freeze protection electric heater (optional)

In conditions that lead to tripping the freeze alarm, the controller energises the heater. The heater remains powered for the entire time that the conditions for the freeze alarm continue. Unlike the low water temperature alarm, which is enabled only when the unit is powered on, the anti-freeze heater can be energised when the machine is on stand-by.

8.2.10 Compressor operation

When the unit is running correctly and no general alarms are present, the microprocessor controller starts the compressors in accordance with the water temperature reading. Compressor starts are staggered in accordance with preset delay intervals, thus avoiding excess input current surges. Before starting a compressor, the microprocessor checks the value of the delivery pressure by means of the relevant transducer, the status of the high pressure switch and the compressor motor windings temperature by checking the thermal protection.

When the compressor has been started, tripping of any of the safety devices will cause the compressor to stop immediately and an alarm will be displayed. While the compressor is running, discharge pressure and suction pressure are monitored constantly by means of the relevant sensors.

On unit start-up the first compressor is started with a delay, set on the microprocessor controller, after the start of the hydraulic system circulating pump. Once started, each compressor must run for a minimum operating period, unless a critical alarm should trip in the meantime. The critical alarms which can stop the compressor during the minimum operating time are the high pressure alarm and the compressor thermal cut-out alarm. Once stopped each compressor can be restarted only after a minimum idle time or after a minimum time interval between two consecutive starts has elapsed. The consecutive starting of two compressors or the consecutive starting of one compressor, is executed with minimum delay intervals equal to the capacity step activation time. Stopping compressors is also performed with a minimum programmed delay interval.

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Models 14.4 - 26.4, controller pCO

8.2.11 Compressor management

Start-up of the compressors is automatic when the reference water temperature changes with respect to the programmed set-point. Normally the reference water temperature is the value detected at the inlet to the chiller unit.

Balancing of duty hours over all the compressors in the unit is performed by selecting the rotation of starts. With the rotation function of starts active, the first compressor to start is the first one that previously stopped. Also the first compressor to start will be the one with the most operating hours.

8.2.12 High and low pressure alarms

Discharge pressure (high pressure) and suction pressure (low pressure) are managed by the microprocessor controller through the relevant sensors. When a compressor is running, the controller checks that:

- Discharge pressure is always lower than the safety value set for cooling or heating mode operation. If the values are exceeded, the controller immediately stops the compressor and displays a high pressure alarm. The high pressure alarm can be reset manually on the controller only when the pressure detected by the discharge pressure sensor is lower than the value that caused the alarm to trip, less the differential value.

- The suction pressure is always higher than the safety value set for operation in cooling or heating mode. If the value read by the suction pressure sensor is lower than the limits set for the relative operating conditions, the controller will stop the compressor and generate a low pressure alarm. The low pressure alarm is not instantaneous, but operates after a preset delay interval, both in the starting phase and during the normal running of the machine. The low pressure alarm can be reset automatically or manually, depending on the relative parameter setting. In all cases the low pressure alarm can only be reset when the pressure detected by the suction sensor is higher than the value that caused the alarm to trip, plus the differential value. It is possible to program the number of permissible consecutive compressor starts before the unit shuts down in safety status.

8.2.13 Changeover from chiller to heat pump and vice versa

The changeover from chiller to heat pump and back can be performed at any time, either by means of an external signal on a digital input, from the keypad, or via the serial line. The operating mode changeover must be only seasonal and only with the unit off. After a mode changeover, the controller re-starts the unit in the new mode with a factory set minimum delay time. The unit operates with temperature control on the inlet to which has been inactive for the longest time. the unit (or return from the system).

8.2.14 Desuperheater (Option)

The desuperheater recovers part of the total power to be dissipated into the condenser to produce hot water (water inlet temperature 40 °C, water leaving temperature 45 °C at design conditions). This is energy efficient and therefore has an economic benefit. Each refrigerant circuit is supplied with a shell and tube desuperheater positioned in series to the main condenser. See paragraph 4.6 for the hydraulic diagram.

8.2.15 Total heat recovery (only SIGMA 2002/DC)

The goal of total heat recovery is to recover 100% of the heat energy that would be rejected in the process to achieve energy efficiency and an economic benefit. SIGMA 2002/DC units have a 100% heat recovery condenser on each refrigeration circuit for the production of hot water (water inlet temperature 40 °C, water leaving temperature 45 °C at design conditions). The heat recovery condenser is positioned between the compressor and the main condenser (see refrigerant diagram). The heat recovery and condenser water circuits are completely independent to allow maximum working flexibility in the use of the water which passes through the heat recovery condenser. With the heat recovery off, (when no water is flowing through the recovery heat exchanger) the unit operates as a standard chiller.

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Models 14.4 - 26.4, controller pCO

8.2.16 Dual set-point (option)

With double thermostatic valves and solenoid valves that are automatically switched according to the required expansion temperature. Two set-point values can be programmed on the microprocessor controller via the keypad or a digital input. Switching of the thermostatic valves is always automatic, in accordance with the water temperature. The valves are sized on the basis of the temperature values specified at the time of the order. The machine operating limits shown in the catalogue are not affected. If the hydraulic circuit contains glycol in sufficient quantities to eliminate the risk of freezing, the lower limit is extended to a minimum of -5 °C leaving water temperature.

8.2.17 Leaving water temperature control (option)

With leaving chilled water temperature control a reference sensor must be installed on the evaporator outlet. The unit's capacity steps are activated / deactivated with delay intervals in relation to a dead zone. When the leaving water temperature is higher than the programmed set-point compressors start is enabled.

8.2.18 Defrost (heat pumps units /LC/HP)

During winter mode operation (heat pump) the the remote condenser finned coil functions as an evaporator, cooling and dehumidifying ambient air. During heat pump operation, the evaporation pressure is monitored to prevent it from falling below a preset value. The evaporation control is active only during heating mode operation. Depending on the ambient air temperature and humidity conditions, condensate or frost will tend to form, consequently obstructing the free passage of air and causing thermal insulation. The frost that builds up on the coil obstructs the passage of air, reduces the available heat exchange surface area (and thus the thermal efficiency), and can damage the exchanger. Defrosting is the procedure that serves to prevent or eliminate the formation of ice on the evaporator coil during heat pump mode operation of an air to water unit. Defrosting is performed simultaneously for the entire unit. All heat pump versions are equipped with a control that activates an automatic coil defrost cycle when necessary. After starting however, the first defrost cycle will be started after a preset minimum operating time to allow the formation of sufficient thermal inertia to allow the cycle to be completed successfully. Defrost cycle demands are based on detection of a low suction pressure value, due to the insufficient heat exchange between the evaporator and the air because of the formation of a layer of ice, which exerts a thermal insulation effect. For a defrost cycle to be able to start the suction pressure of at least one of the currently operating compressors must remain below the pressure set for the defrost cycle trip signal for a given time interval. Before starting to defrost the coils, all the compressors are started, after which the unit is switched from heat pump to cooling mode. When the cycle is reversed the fans stop and the compressors force hot gas into the coil. A pressure switch on the high pressure circuit maintains the gas discharge pressure below the defrost end value. To maintain the pressure lower than the defrost end pressure the pressure switch activates the fans. To reduce the air flow, and obtain more efficient heating of the outer part of the coil, the pressure switch signal causes the fans to rotate in reverse. On remote condensers/evaporators supplied by Blue Box when the defrost end temperature is reached, as measured by a thermostat with the relative sensor located in the lower part of the coil, the pressure switch allows the delivery pressure to reach the defrost end pressure. With remote condensers/evaporators not supplied by Blue Box the heat exchanger is controlled by pressure only. When the defrost end pressure has been reached the controller reverses the unit from chiller mode to heat pump mode thereby terminating the defrost procedure. Even though in certain conditions the surface temperature of the coil and the condensation pressure fail to reach the defrost values, within the preset time limit, the defrost cycle is forcibly terminated as though the defrost end signal were present. The controller restarts the fans and when the pressure returns to the preset value it reverses the unit's operating mode again. If the defrost cycle is forcibly interrupted with the timeout signal it is signalled on the display even though no

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Models 14.4 - 26.4, controller pCO

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Models 14.4 - 26.4, controller pCO

8.3 STARTING THE UNIT

For the start-up procedure refer also to the microprocessor controller manual.

- Close the external enabling contacts

- Press the "ON" button on the microprocessor controller

- If all the controls are enabled the display will show the message "UNIT ON" After having performed the above procedures the unit will start automatically after a delay of approximately 5

minutes, assuming that the enabling signals of the microprocessor, the flow switches, and the water pumps continue to be present.

If the unit fails to start: do not change internal electrical connections on penalty of immediate invalidation of the warranty.

8.4 STOPPING THE UNIT

8.4.1 Temporary stop:

- To stop the unit press the "OFF" button on the front panel.

8.4.2 Seasonal stop:

- Disconnect the power supply

- Drain the system circuit (unless it contains a water/glycol solution)

- When the unit is to be restarted repeat the initial start-up procedure

Figure 31

Warning: do not use the machine main power switch to stop the unit: this switch must be used to disconnect the electrical supply when no current is flowing on the circuit, i.e. only when the unit is in OFF status. Note also that if power is disconnected from the unit, the crankcase heaters will be switched off with the resulting risk of compressor damage at the time of restarting.

8.5 EMERGENCY STOP

Emergency stops are obtained by turning the red colour main disconnect switch on the electrical panel to position 0.

Figure 32

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Models 14.4 - 26.4, controller pCO

9. TROUBLESHOOTING

In relation to possible corrective action, adopt the maximum attention in the operations you intend to perform as overconfidence coupled with insufficient attention due to lack of expertise can lead to serious accidents. We therefore recommend that Blue Box or other skilled HVAC engineers are contacted to identify and correct the problem.

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Page 86

Models 14.4 - 26.4, controller pCO

SYMPTOM

COOLING

OPERATION

HEATING

PROBABLE CAUSE

A) No compressor running

⊗ ⊗

No mains power Check presence of mains power

(display Off)

⊗ ⊗

Main power switch Off (position "O")

⊗ ⊗

Transformer fuses and/or fuses 24 V burnt-out

⊗ ⊗

Electronic control card faulty

B) No compressor

⊗ ⊗

No external consent Check presence of external running. Display On: ”OFF from external consent”

C) No compressor running. Display On:

⊗ ⊗

No consent from

supervision system ”OFF from supervision system”

D) No compressor running. Display On:

⊗ ⊗

No consent from “on/off”

key of user interface ”OFF”

POSSIBLE CORRECTIVE ACTION

Turn main power selector to position "I"

Check fuses and if necessary replace burned out fuses (FU50 and FU51). If fuses burn-out again call for assistance

Call assistance

consent; if not present, bridge terminals 1 and 2

Activate operation from supervision system

Press “on/off” key

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Models 14.4 - 26.4, controller pCO

SYMPTOM

COOLING

OPERATION

HEATING

PROBABLE CAUSE

E1) No compressor running. Display On: unit ON with alarm “High Pressure Compressor 1, 2, 3, 4”

⊗ ⊗

⊗

220V fuses burnt-out (FU51) (in version LC and LC/HP also the alarm “Fans protection” will be displayed)

Insufficient condenser

water flow

⊗ ⊗

Entering condenser water temperature too high

⊗ ⊗

The unit has an excessive refrigerant charge (only version LC and LC/HP)

⊗ ⊗

Remote condenser faulty (only LC version LC and LC/HP)

E2) No compressor running. Display On: unit ON with alarm “Thermal protections Compressor 1, 2, 3, 4”

⊗ ⊗

Entering condenser water temperature too high

Drop in power feeding voltage

⊗ ⊗

Setting of thermal protections

⊗ ⊗

Circuits partially discharged Call service to replenish charge

POSSIBLE CORRECTIVE ACTION

Change fuses. If fuses burn-out again contact assistance

Check hydraulic circuit and condenser water flow

Check hydraulic circuit of condenser

Call assistance

Check flow and temperature of condenser entering water

Check voltage stability and fit appropriate protection if necessary

Contact assistance

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Models 14.4 - 26.4, controller pCO

SYMPTOM

COOLING

OPERATION

HEATING

PROBABLE CAUSE

E3) No compressor running. Display On: unit ON with alarm “Low Pressure Compressor 1, 2, 3, 4”

⊗ ⊗

Insufficient percentage of

glycol in hydraulic circuit

Both circuits have

insufficient refrigerant

charge

⊗

Incorrect setting of defrost

set-point (only version

LC/HP)

E4) No compressor running. Display On:

⊗ ⊗

Insufficient water flow to

evaporator unit ON with alarm “Exceeded Threshold Low Temperature of leaving User Water”.

⊗ ⊗

Faulty controller Contact service organisation

E5) No compressor

⊗ ⊗

Excessive thermal load Wait until entering water running. Display On: unit ON with alarm “Exceeded Threshold High Temperature of entering User Water

⊗ ⊗

Refrigerant circuits partially

discharged

E6) (Only version LC) No compressor

⊗ ⊗

Depending upon the fan

type installed running. Display On: unit ON with alarm “Fans protection”

POSSIBLE CORRECTIVE ACTION

Restore correct glycol percentage

Find possible leaks in circuit, repair, and recharge

Check and correct setting if necessary

Increase water flow to evaporator and check temperature rise

temperature is below the alarm set point. Start hydraulic circuit of evaporator and unit. If not sufficient contact assistance.

Call assistance

Check thermal consent of fans

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Models 14.4 - 26.4, controller pCO

SYMPTOM

COOLING

OPERATION

HEATING

PROBABLE CAUSE

E7) No compressor running. Display On:

⊗ ⊗

Power supply voltage not

stable unit ON with alarm “No power to Control circuits”

F1) No compressor running. Display On: unit OFF with alarm “Flow Switch Alarm”

⊗ ⊗

No water flow to

evaporator

Flow switch faulty Check flow switch contact and

F2) No compressor

⊗ ⊗

Incorrect phase sequence Invert two of the phase wires of running. Display On: unit OFF with alarm ”Incorrect Phase Sequence” and phase sequence relay with green LED On and orange LED Off

F3) No compressor

⊗ ⊗

Faulty relay Check to ensure that relay closes running. Display On: unit OFF with alarm ”Incorrect Phase Sequence” and phase sequence relay with green and orange LEDs On

F4) No compressor

⊗ ⊗

Fuses FU56 burnt-out Check fuse FU56 and replace if running. Display On: unit OFF with alarm ”Incorrect Phase Sequence” and phase sequence relay with green and

⊗ ⊗

One of the three phases is

not present orange LEDs Off

POSSIBLE CORRECTIVE ACTION

Check power supply voltage; if not correct contact the electricity company

Check hydraulic circuit

replace if necessary

the power supply line

contact

necessary

Check connection of each phase

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Models 14.4 - 26.4, controller pCO

SYMPTOM

COOLING

OPERATION

HEATING

PROBABLE CAUSE

G) No compressor running. Display On:

⊗ ⊗

No consent from digital input to compressors

unit ON without alarm

⊗ ⊗

Unit at temperature Normal operation

⊗ ⊗

Compressor fuses burntout

⊗ ⊗

Controller faulty Call service

H1) Only 1 compressor

⊗ ⊗

Excess refrigerant charge Check refrigerant charge and call running. Display On with alarm “High Pressure Compressor 1 and 2 or 3 and 4”

⊗ ⊗

Problems at the condenser

hydraulic circuit

⊗ ⊗

High pressure switch

incorrectly calibrated or

faulty

⊗ ⊗

Pressostatic valve

incorrectly set

H2) Only 1 compressor running. Display On with alarm

⊗ ⊗

Insufficient refrigerant

charge due to a leak in the

circuit “Low Pressure Compressor 1 and 2 or 3 and 4”

⊗ ⊗

Thermostatic valve faulty Call service

⊗ ⊗

Solenoid valve of liquid

refrigerant line faulty (if

present)

⊗ ⊗

Dehydrating filter clogged Call service

POSSIBLE CORRECTIVE ACTION

Check consent to compressors and close relative contacts

Check continuity of fuses; if burnt-out call service

service organisation

Check flow and temperature of condenser entering water

Check pressure switch setting

Check setting of pressostatic valve and call assistance

Call service

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Models 14.4 - 26.4, controller pCO

SYMPTOM

COOLING

OPERATION

HEATING

PROBABLE CAUSE

H3) One, two or three

⊗ ⊗

Problems at the compressor Call service compressors running. Display On with alarm “Compressor Thermal Protections”

I) Only one compressor

⊗ ⊗

Unit capacity step active Normal operation Running. Display On without alarms

⊗ ⊗

Fuses burnt-out Call service

⊗ ⊗

Controller faulty Call service

⊗ ⊗

No external consent to the

compressor

L1) All compressors running. Display On

⊗ ⊗

Compressors specified by

alarm require maintenance with alarm “Compressor Maintenance”

L2) All compressors

⊗ ⊗

Unit maintenance required Call service for scheduled running. Display On with alarm “Unit Maintenance”

M) All compressors running without stopping. Display On without alarm

⊗ ⊗

Excess thermal load Call service

Refrigerant circuits partially discharged

⊗ ⊗

Controller not working Call service

POSSIBLE CORRECTIVE ACTION

Check external consent of compressor

Call service for scheduled maintenance

maintenance

Call service

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Models 14.4 - 26.4, controller pCO

SYMPTOM

N) Anomalous noise from system

OPERATION

COOLING

⊗ ⊗

HEATING

PROBABLE CAUSE

POSSIBLE CORRECTIVE ACTION

Compressor noisy Contact service to check and

replace if necessary

Thermostatic valve noisy Contact service to check and add

refrigerant

Vibrating pipes Contact service organisation to

secure pipes

Casing panels vibrate Check that panels are properly

fastened; contact service organisation if necessary

If the display presents alarms other than those described above, contact the service organisation.

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10 CHECKS DURING OPERATION

- With the unit at steady conditions check that the entering and leaving condenser water temperatures are inside the operating limits given in the technical specifications.

10.1 Checking the refrigerant charge

- After a few hours of unit operation check that the sight glass moisture indicator has a green coloured core. if the core is yellow, moisture is present in the circuit. In such a situation the circuit must be dehydrated by a qualified technician.

- Check the sight glass for air bubbles. A constant passage of bubbles through the sight glass could indicate that the refrigerant must be replenished. Occasional bubbles are considered normal.

- A few minutes after the start of the compressors, check that the condensing temperature, equivalent to the pressure read on the pressure gauge, is approximately 8 °C higher than condenser inlet water temperature. Also check that the evaporating temperature, equivalent to the pressure read on the pressure gauge, is 5 °C lower than the evaporator outlet temperature.

- Check that the refrigerant superheating is between 5 and 7 °C; to do this:

1) measure the temperature using a contact thermometer placed on the compressor suction pipeline;

2) read the temperature, equivalent to the pressure read on the pressure gauge connected to the compressor suction side (saturation temperature corresponding to suction pressure); for units charged with R407C refrigerant, refer to the D.P. (Dew Point) pressure gauge scale.

The difference between the temperatures measured in this manner is equivalent to the superheating value.

- Check that refrigerant subcooling is between 5 and 7 °C; to do this:

1) measure the temperature using a contact thermometer placed on the compressor discharge pipeline;

2) read the temperature, equivalent to the pressure read on the pressure gauge connected to the liquid connection at the condenser outlet (saturation temperature corresponding to condenser delivery pressure); for units charged with R407C refrigerant, refer to the B.P. (Bubble Point) pressure gauge scale.

The difference between the temperature values measured in this manner is equivalent to the subcooling value.

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11. CALIBRATION OF CONTROL EQUIPMENT

11.1 INTRODUCTION

All the control equipment is factory calibrated before the machine is shipped. Control equipment and safety devices should nonetheless be checked after a reasonable period of operation. Calibration values are given in Tables 5 and 6.

All service operations on the control equipment must be carried out by QUALIFIED PERSONNEL ONLY; incorrect calibration values can cause serious damage to the unit and personal injury.

TABLE 5 - CALIBRATION OF CONTROL EQUIPMENT

CAPACITY STEPS CONTROL ELEMENT SET POINT DIFFERENTIAL SET POINT DIFFERENTIAL

Service calibration (summer) °C 10 2 9 3 Service calibration (winter) °C 42 2 43 3

2 4

TABLE 6 - CALIBRATION OF SAFETY DEVICES

CONTROL ELEMENT

No-frost setting °C 3 6 manual Maximum pressure switch setting bar 27 7 manual Minimum pressure switch setting bar 2.5 / 0.7 (*) 1 manual (from controller) Evaporator heater setting °C 3 6 automatic Defrost start setting bar 2 -- automatic Defrost end setting bar 18 -- automatic Defrost end thermostat setting °C 5 -- automatic Defrost pressure switch setting bar 16 2 automatic

ACTIVATION DIFFERENTIAL RESET

SET POINT

NOTE: (*) Chiller / Version HP/LC (**) Only version HP/LC with remote condensers/evaporators supplied by Blue Box

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12. MAINTENANCE AND PERIODIC CHECKS

12. 1 WARNINGS

All operations described in this chapter MUST BE PERFORMED EXCLUSIVELY BY QUALIFIED PERSONNEL.

Make sure that the unit has been disconnected from the power supply before carrying out any work or accessing internal parts.

12.2 INTRODUCTION

Carry out the following periodic checks to ensure the unit is operating correctly:

The compressor head and discharge pipeline can reach high temperatures. Always exert caution when working in the vicinity of the compressor.

CHECK PERIOD

Check that safety and control devices work correctly as previously described monthly Check all the terminals on electric board and compressor are well locked. Periodic cleaning of the sliding terminals of the contactors should be done: if any damage is found, replace the contactors Check the sight glass to verify the refrigerant charge. monthly Check there is no oil leakage from compressor monthly Check there is no water leakage in the hydraulic system monthly If the unit is to be stopped for a long period the hydraulic circuit, including all pipes and heat exchangers, should be drained. This is compulsory if the ambient temperature is expected to fall below the freezing point of the liquid employed. Check process water levels monthly Check that the flow switch is operating correctly. monthly Check that the crankcase heater operating correctly and the power supply. monthly Clean metallic filters on water piping monthly Check the colour of the sight glass core (green = no moisture, yellow = moisture present): if it has a yellow colour, change the refrigerant filter Check that the noise level has not increased. every 4 months

monthly

seasonal

operation

every 4 months

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12.3 REPAIRING THE REFRIGERANT CIRCUIT

If repairs have been made to the refrigerant circuit, perform the following steps:

- leak test;

- vacuum and dehydration of refrigerant circuit;

- refrigerant charge.

If the circuit is to be emptied, use the appropriate equipment to collect the refrigerant.

12.3.1 Leak test

Charge the refrigerant circuit to a pressure of 15 bar with dry nitrogen gas by means of a cylinder fitted with a pressure reducer. Check the circuit for leaks with a leak detector. The formation of bubbles or foam indicates the presence of leaks. If leaks are found during the test, empty the refrigerant circuit and then repair the point of leakage by welding with appropriate alloys.

Do not use oxygen instead of nitrogen: explosion hazard.

12.3.2 High vacuum and dehydration of the refrigerant circuit

To generate a high vacuum in the refrigerant circuit use a high vacuum pump able to reach 0.1 mbar of absolute pressure with a flow rate of 10 m3/h. With this type of pump, a single vacuum cycle is normally sufficient to reach an absolute pressure of 0.1 mbar. If this type of pump is not available, or in the event that the circuit has been left open for a long period of time, you are strongly advised to use the triple evacuation method. This procedure is also prescribed in the event of moisture in the refrigerant circuit.

Connect the vacuum pump to the charge connector. Proceed as follows:

- Evacuate the circuit to a pressure of at least 35 mbar absolute. Charge the circuit with nitrogen to a relative pressure of approx. 1 bar.

- Repeat the operation described above.

- Repeat the operation described above for the third time in order to reach the highest degree of vacuum possible.

This procedure should guarantee the elimination of up to 99% of contaminants.

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12.3.3 Refrigerant charge

- Connect the refrigerant gas cylinder to the male 1/4 SAE charge connector on the liquid line and allow a small amount of gas to escape in order to purge the connection hose of air.

- The circuit must be charged exclusively with liquid; therefore, if the cylinder is not equipped with a dip pipe it must be turned upside-down.

12.4 ENVIRONMENTAL CONSIDERATIONS

Laws governing the use of substances detrimental to the ozone layer prohibit the dispersal of refrigerant gases in the environment, obliging users to recover refrigerants at the end of their useful life and consign them to the dealer or to specific collection centres. Refrigerants R22 and R407C are mentioned among substances subject to special monitoring regimes established by law, and as such they are subject to the prescriptions indicated above.

Units operating with R407C must be charged exclusively with liquid refrigerant by way of the charge connection on the liquid line.

Use special care during maintenance work in order to limit the risk of refrigerant leakage as far as possible.

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13. DECOMMISSIONING THE UNIT

When the unit has reached the end of its useful life and must therefore be removed and replaced, adhere to the following rules:

- the refrigerant must be recovered by a qualified technician and sent to an authorised collection centre;

- also the compressor lubrication oil must be recovered and sent to a collection centre;

- the structure and components, if unusable, must be stripped down and separated according to the material type; this is particularly important for copper and aluminium, which are fairly abundant on the machine.

This procedure is designed to assist the work of collection, disposal, and recovery specialists and to reduce the associated environmental impact.

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REFRIGERANT CIRCUIT DIAGRAM

SIGMA 2002 - SIGMA 2002/DC - MODELS 3.2 - 13.2

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REFRIGERANT CIRCUIT DIAGRAM

SIGMA 2002 - SIGMA 2002/DC - MODELS 14.4 - 26.4

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Blue Box SIGMA 2002 Installation, Installation, Operating, Operating, And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual